Sloped Roof Solar Panel Mounting System

ABSTRACT

A mounting system for supporting a plurality of photovoltaic modules on a sloped support surface, such as a sloped roof, is disclosed herein. The mounting system may include one or more support surface attachment devices, each support surface attachment device configured to attach one or more photovoltaic modules to a support surface; and one or more module coupling devices, each module coupling device configured to couple a plurality of photovoltaic modules to one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to U.S. Provisional PatentApplication No. 62/131,743, entitled “Sloped Roof Solar Panel MountingSystem”, filed on Mar. 11, 2015; and further claims priority to U.S.Provisional Patent Application No. 62/192,529, entitled “Sloped RoofSolar Panel Mounting System”, filed on Jul. 14, 2015, the disclosure ofeach of which is hereby incorporated by reference as if set forth intheir entirety herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the present invention generally relates to mounting systemsand, more particularly, to support assemblies and mounting systems formounting photovoltaic modules or panels on sloped support surfaces suchas, for example, sloped building rooftops, or the like.

2. Background

There is a need for a sloped roof solar panel mounting system thatattaches to rafters or roof supporting members, avoids using rails orstruts, and is universal.

Solar panels must be secured to the roof and underlying structure todisperse wind and snow loads into the building structure. Although somemounting systems that avoid using rails attach to the roof decking, theydo not attach to the roof rafters because the spacing of rafters isdifferent than the length of modules.

Rails and struts are long extrusions or roll-formed strips that must becut to length, use excess material, are costly to manufacture and highin shipping cost. Therefore, a mounting system avoiding the use of railsor struts is desired.

There is a need for the system to mount to any solar module on themarket, giving installers the flexibility to choose the module of theirchoice, rather than be required to buy a module with a custom profilerail to accommodate the mounting system.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

Accordingly, the present invention is directed to a sloped roof solarpanel mounting system that substantially obviates one or more problemsresulting from the limitations and deficiencies of the related art.

In accordance with one or more embodiments of the present invention,there is provided a support surface attachment device, the supportsurface attachment device configured to attach one or more photovoltaicmodules to a support surface. The support surface attachment deviceincluding a base assembly configured to be attached to a supportsurface; and a clamp assembly configured to engage one or morephotovoltaic modules, the clamp assembly including a lower clamp memberand an upper clamp member, the upper clamp member connected to the lowerclamp member by a fastener member, the lower clamp member including oneor more first teeth disposed thereon, and the upper clamp memberincluding one or more second teeth disposed thereon, the one or morefirst teeth on the lower clamp member configured to engage the one ormore second teeth on the upper clamp member when the fastener is beingtightened so as to maintain a minimum gap between the upper clamp memberand the lower clamp member for receiving one or more photovoltaic moduleframes of the one or more photovoltaic modules when the one or morephotovoltaic modules are pivotably installed into a first side of theclamp assembly. The clamp assembly is capable of being selectivelypositioned along a length of the base assembly prior to being fixed inplace relative to the base assembly so as to permit adjustability whenthe one or more photovoltaic modules are being attached to the supportsurface.

In a further embodiment of the present invention, the upper clamp memberof the clamp assembly comprises one or more grooves for receiving aportion of a bonding clip for grounding the one or more photovoltaicmodules.

In yet a further embodiment, the support surface attachment devicefurther comprises a spring member disposed between the upper clampmember and the lower clamp member of the clamp assembly, the springmember configured to hold the clamp assembly open for facilitating theinstallation of the one or more photovoltaic modules into the clampassembly, and the spring member further configured to enable the clampassembly to be secured on the base assembly while maintaining theminimum gap between the upper clamp member and the lower clamp member.

In still a further embodiment, the support surface attachment devicefurther comprises a strut nut threadingly coupled to the fastenermember, the strut nut configured to fix the clamp assembly in placerelative to the base assembly when the fastener member is tightened.

In yet a further embodiment, the fastener member comprises a visualindicator line formed on a head portion of the fastener member forindicating an orientation of the strut nut.

In still a further embodiment, the support surface attachment devicefurther comprises a glider member coupling the upper and lower clampmembers of the clamp assembly to the base assembly, the glider memberconfigured to slide relative to the base assembly so as to allow theclamp assembly to be selectively positioned along the length of the baseassembly prior to being fixed in place relative to the base assembly.

In yet a further embodiment, the glider member comprises one or moreprotrusions or grooves formed in an outer side of the glider member, theone or more protrusions or grooves configured to serve as a visualindicator indicating a height of the clamp assembly relative to the baseassembly and/or serve as a means for holding a chalk line during aninstallation of the one or more photovoltaic modules.

In yet a further embodiment, the upper and lower clamp members of theclamp assembly are configured to rotate together relative to the glidermember, and wherein an upstanding base member of the base assembly isconfigured to rotate relative to the support surface, whereby therotation of the upper and lower clamp members relative to the glidermember and the rotation of the upstanding base member of the baseassembly relative to a flashing member of the support surface attachmentdevice enables a lateral position of the clamp assembly to be adjustedby an installer.

In still a further embodiment, the lower clamp member of the clampassembly comprises one or more ridges disposed on a bottom surface ofthe lower clamp member, the one or more ridges configured to increase africtional engagement between the lower clamp member and the glidermember so as resist the upper and lower clamp members of the clampassembly from rotating relative to the glider member when the fastenermember is tightened by an installer.

In yet a further embodiment, base assembly includes an upstanding basemember, the upstanding base member comprising one or more mating groovesand one or more mating protrusions for engaging with one or more matingprotrusions and one or more mating grooves of the glider member, whereina selected engagement between the one or more mating grooves andprotrusions of the upstanding base member and the one or more matinggrooves and protrusions of the glider member enables the clamp assemblyto be selectively positioned at a predetermined height relative to thebase assembly prior to being fixed in place relative to the baseassembly so as to permit vertical adjustability when the one or morephotovoltaic modules are being attached to the support surface.

In still a further embodiment, the upper clamp member of the clampassembly comprises a first downwardly protruding member and a seconddownwardly protruding member spaced apart from the first downwardlyprotruding member by a gap, the second downwardly protruding memberbeing shorter in length than the first downwardly protruding member, andthe second downwardly protruding member configured to provide anabutment surface for a skirt member.

In yet a further embodiment, the lower clamp member of the clampassembly comprises one or more mating grooves and one or more matingprotrusions for engaging with one or more mating protrusions and one ormore mating grooves of a skirt member.

In still a further embodiment, the one or more mating protrusions on thelower clamp member are upwardly inclined so as to enable the skirtmember to be inserted into the clamp assembly from above duringinstallation, and so as to prevent the skirt member from becomingdisengaged from the clamp assembly after the installation of the skirtmember.

In yet a further embodiment, the upper clamp member of the clampassembly comprises a pair of downwardly extending lip portions onopposite sides of a top portion of the upper clamp member, a first oneof the pair of downwardly extending lip portions being longer than asecond one of the pair of downwardly extending lip portions so as tofacilitate the one or more photovoltaic modules being pivotablyinstalled into the first side of the clamp assembly.

In still a further embodiment, the lower clamp member of the clampassembly comprises an upwardly tapered ledge extending outwardly fromthe first side of the clamp assembly, the upwardly tapered ledgeconfigured to support the one or more photovoltaic module frames of theone or more photovoltaic modules, and the upwardly tapered ledge beingconfigured to function as a spring for applying a compressive forceagainst the one or more photovoltaic module frames of the one or morephotovoltaic modules so as to securely retain the one or morephotovoltaic modules in the clamp assembly after the one or morephotovoltaic modules are pivotably installed.

In yet a further embodiment, the base assembly includes an upstandingbase member, the upstanding base member including a pair of verticallyspaced-apart bottom wall portions, a first of the pair of verticallyspaced-apart bottom wall portions comprising a first aperture and asecond of the pair of vertically spaced-apart bottom wall portionscomprising a second aperture, the first and second apertures of theupstanding base member configured to receive a raised portion of aflashing member therein so as to permit a fastener aperture disposed inthe flashing member to be elevated above the support surface, therebyenabling the support surface attachment device to be more leakageresistant.

In yet a further embodiment, the upstanding base member of the baseassembly further comprises one or more base flange portions, the one ormore base flange portions having one or more mounting apertures disposedtherethrough, the one or more mounting apertures configured to receiveone or more respective fasteners for securing the upstanding base memberto the support surface.

In still a further embodiment, a bottom surface of the upstanding basemember comprises one or more ridges disposed thereon, the one or moreridges configured to increase a frictional engagement between theupstanding base member and the flashing member so as prevent theupstanding base member from rotating relative to the flashing memberwhen a base fastener member is tightened by an installer.

In yet a further embodiment, the one or more ridges disposed on thebottom surface of the upstanding base member are additionally configuredto capture and hold sealing tape when the upstanding base member ismounted directly against the support surface.

In still a further embodiment, a top surface of the upstanding basemember comprises one or more visual installation guide marks configuredto facilitate an installation of one or more rows of the one or morephotovoltaic modules.

In yet a further embodiment, the support surface attachment devicefurther comprises a flashing member having a fastener apertureconfigured to receive a base fastener member for attaching an upstandingbase member of the base assembly and the flashing member to the supportsurface, the fastener aperture being disposed through a raised positionof the flashing member so that water is prevented from passing throughthe fastener aperture.

In yet a further embodiment, the support surface attachment devicefurther comprises a sealing washer configured to be disposed between ahead of the base fastener member and a top rim of the raised position ofthe flashing member, the sealing washer including an upper portionformed from a first material and a lower portion formed from a secondmaterial, the first material forming the upper portion of the sealingwasher restricting a deformation of the second material forming thelower portion of the sealing washer so as to prevent the sealing washerfrom entering the fastener aperture in the flashing member.

In still a further embodiment, the lower portion of the sealing washerfurther comprises a tapered bottom surface so as to tightly engage thetop rim of the raised portion of the flashing member and to prevent thesecond material forming the lower portion of the sealing washer fromentering the fastener aperture in the flashing member.

In yet a further embodiment, the raised portion of the flashing membercomprises a circumferential ledge portion, wherein, when the upstandingbase member of the base assembly is assembled with the flashing member,a top surface of the circumferential ledge portion of the raised portionof the flashing member is configured to regulate a height of an uppersection of the raised portion of the flashing member that is disposedabove the circumferential ledge portion so that a top rim of the uppersection of the raised portion does not protrude substantially above atop surface of an elevated shelf of the upstanding base member.

In still a further embodiment, the support surface attachment devicefurther comprises a cantilevered mounting arm coupling the clampassembly to the base assembly, the cantilevered mounting arm configuredto support the clamp assembly in a cantilevered manner from the baseassembly so that the clamp assembly is capable of being horizontallyoffset from the base assembly, thereby allowing one or more edges of theone or more photovoltaic modules to be disposed above a region of thesupport surface that is unable to accommodate the base assembly.

In yet a further embodiment, the region of the support surface that isunable to accommodate the base assembly comprises an area at or near aroof ridge, and wherein the cantilevered mounting arm enables one ormore additional photovoltaic modules to be installed proximate to theroof ridge.

In still a further embodiment, the support surface attachment devicefurther comprises an electrical accessory bracket configured to mount anelectrical accessory of a photovoltaic system to an upstanding basemember of the base assembly, the electrical accessory bracket comprisingat least one flange portion configured to attach the electricalaccessory bracket to the upstanding base member, the electricalaccessory bracket further comprising a bracket base portion comprisingone or more mounting apertures for attaching the electrical accessory tothe electrical accessory bracket.

In yet a further embodiment, the at least one flange portion of theelectrical accessory bracket is offset from a center position of thebracket base portion in a widthwise direction of the bracket baseportion so as to facilitate a connection of one or more wires to theelectrical accessory without the upstanding base member of the baseassembly interfering with a routing of the one or more wires.

In still a further embodiment, the bracket base portion of theelectrical accessory bracket comprises a plurality of slots formedtherein for accommodating various electrical accessories, and whereinthe at least one flange portion of the electrical accessory bracketcomprises at least one aperture formed therein for accommodating agrounding lug.

In yet a further embodiment, the support surface attachment devicefurther comprises a conduit mounting member configured to mountelectrical conduit of a photovoltaic system to an upstanding base memberof the base assembly, the conduit mounting member including a securementportion comprising one or more mounting apertures for attaching theconduit mounting member to the upstanding base member, the conduitmounting member further comprising a conduit mounting portion connectedto the securement portion, the conduit mounting portion comprising oneor more securement apertures for attaching the electrical conduit to theconduit mounting member.

In accordance with one or more other embodiments of the presentinvention, there is provided a coupling device configured to attach oneor more photovoltaic modules to one or more other photovoltaic modules.The coupling device including a lower coupling member including at leastone ledge extending outwardly from a side surface of the lower couplingmember, the lower coupling member further including one or more firstteeth disposed thereon; and an upper coupling member including at leastone flange portion extending outwardly from the upper coupling member,the upper coupling member further including one or more second teethdisposed thereon, the upper coupling member being adjustably connectedto the lower coupling member by at least one fastening device, the oneor more first teeth on the lower coupling member configured to engagethe one or more second teeth on the lower coupling member when the atleast one fastening device is being tightened so as to maintain aminimum gap between the upper coupling member and the lower couplingmember for receiving one or more photovoltaic module frames of the oneor more photovoltaic modules when the one or more photovoltaic modulesare pivotably installed into a first side of the clamp assembly. The oneor more other photovoltaic modules are configured to be clamped betweenthe at least one ledge of the lower coupling member and the at least oneflange portion of the upper coupling member.

In a further embodiment of the present invention, the at least oneflange portion of the upper coupling member comprises a plurality ofspaced-apart apertures disposed thererough, and wherein the at least onefastening device comprises a first and second fastening device, a firstone of the plurality of spaced-apart apertures comprising a fastenerhole for receiving the first fastening device, and the second one of theplurality of spaced-apart apertures comprising a fastener slot forreceiving the second fastening device, the fastener slot providingclearance so as to allow the tightening of one of the first and secondfastening devices prior to the tightening of the other of the first andsecond fastening devices.

In yet a further embodiment, the at least one flange portion of theupper coupling member comprises a central slot disposed between thefirst one of the plurality of spaced-apart apertures and the second oneof the plurality of spaced-apart apertures, the central slot configuredto receive a fastener member for connecting the coupling device to aglider member of a support surface attachment device so that thecoupling device is capable of being used with a base assembly of thesupport surface attachment device for attaching the one or morephotovoltaic modules to a support surface.

In still a further embodiment, a top surface of the at least one flangeportion of the upper coupling member comprises one or more visualinstallation guide marks to indicate locational limits of mounting theone or more photovoltaic modules within the coupling device.

In yet a further embodiment, the lower coupling member comprises one ormore mating grooves and one or more mating protrusions for engaging withone or more mating protrusions and one or more mating grooves of a skirtmember.

In still a further embodiment, the one or more mating protrusions of thelower coupling member comprise a plurality of mating protrusionsdisposed in alternating upward and downward orientations so that thecoupling device is capable of remaining in engagement with the skirtmember prior to the at least one fastening device being tightened by aninstaller.

In yet a further embodiment, the lower coupling member comprises one ormore water drainage troughs formed therein for draining water from theone or more photovoltaic modules.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a bonding clip configured to ground one ormore photovoltaic modules. The bonding clip includes a clip body portionhaving a first surface and a second surface disposed opposite to thefirst surface, the clip body portion further including a plurality ofprotruding members, at least one of the plurality of protruding membersprojecting outwardly from the first surface in a first direction, and atleast another of the plurality of protruding members projectingoutwardly from the second surface in a second direction, the firstdirection being generally opposite to the second direction; and one ormore clip attachment portions connected to the clip body portion, theone or more clip attachment portions configured to attach the bondingclip to an object on which the bonding clip is mounted.

In a further embodiment of the present invention, the plurality ofprotruding members are arranged in a generally staggered pattern along alength of the clip body portion.

In yet a further embodiment, the clip body portion is in the form offlat plate that does not comprise any folds formed therein.

In still a further embodiment, the one or more clip attachment portionscomprise a plurality of bent tab members, the plurality of bent tabmembers configured to engage with a groove in the object.

In yet a further embodiment, the one or more clip attachment portionscomprise a pair of flange members, each of the pair of flange membersbeing disposed at an opposite end of the clip body portion; and wherein,when the bonding clip is installed on the object, a top portion of eachof the pair of flange members remains visible to an installer so that aninstalled condition of the bonding clip is capable of being verified bythe installer.

In accordance with still one or more other embodiments of the presentinvention, there is provided a power accessory bracket configured toattach one or more power accessories of a photovoltaic system to one ormore frames of one or more photovoltaic modules. The power accessorybracket includes a bracket body portion having a first side and a secondside disposed opposite to the first surface; a first plurality of teethdisposed on the first side of the bracket body portion, the firstplurality of teeth configured to engage the one or more frames of theone or more photovoltaic modules; and a second plurality of teethdisposed on the second side of the bracket body portion, the secondplurality of teeth configured to engage one or more mounting members ofthe one or more power accessories. The power accessory bracket isconfigured to provide electrical bonding of the one or more photovoltaicmodules to the one or more power accessories.

In a further embodiment of the present invention, at least one of thefirst and second pluralities of teeth extend below a bottom surface ofthe bracket body portion so as to provide the electrical bonding and toaccommodate a plurality of different photovoltaic module flangedimensions.

In yet a further embodiment, the bracket body portion comprises at leastone mounting aperture disposed therethrough, the at least one mountingaperture being offset from a center position of the bracket body portionin a widthwise direction of the bracket body portion so as toaccommodate a plurality of different photovoltaic module flangedimensions by allowing the power accessory bracket to positioned in twodifferent orientations.

In still a further embodiment, the bracket body portion comprises atleast one additional aperture formed therein for accommodating one ormore components of one or more power accessories.

It is to be understood that the foregoing general description and thefollowing detailed description of the present invention are merelyexemplary and explanatory in nature. As such, the foregoing generaldescription and the following detailed description of the inventionshould not be construed to limit the scope of the appended claims in anysense.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will now be described, by way of example, with referenceto the accompanying drawings, in which:

FIG. 1 is a perspective view of a support surface attachment device of aphotovoltaic mounting system, according to a first embodiment of theinvention, wherein the support surface attachment device is illustratedin an assembled state;

FIG. 2 is another perspective view of the support surface attachmentdevice of FIG. 1, wherein a clamp assembly of the support surfaceattachment device is shown exploded from a base assembly of the supportsurface attachment device;

FIG. 3 is a perspective view of the clamp assembly of the supportsurface attachment device of FIG. 1, wherein the clamp assembly isillustrated in an assembled state;

FIG. 4 is another perspective view of the clamp assembly of the supportsurface attachment device of FIG. 1, wherein the components of the clampassembly are shown exploded from one another;

FIG. 5 is a perspective view of a fastener member of the clamp assemblyof FIG. 3;

FIG. 6 is a perspective view of an upper clamp member of the clampassembly of FIG. 3;

FIG. 7 is a perspective view of a bonding clip of the clamp assembly ofFIG. 3;

FIG. 8 is a perspective view of a sleeve member of the clamp assembly ofFIG. 3;

FIG. 9 is a perspective view of a lower clamp member of the clampassembly of FIG. 3;

FIG. 10 is a perspective view of a washer of the clamp assembly of FIG.3;

FIG. 11 is a perspective view of a glider member of the clamp assemblyof FIG. 3;

FIG. 12 is a bottom perspective view of a strut nut of the clampassembly of FIG. 3;

FIG. 13 is a top plan view of the strut nut of FIG. 12;

FIG. 14 is a perspective view of the base assembly of the supportsurface attachment device of FIG. 1, wherein the base assembly isillustrated in an assembled state;

FIG. 15 is another perspective view of the base assembly of the supportsurface attachment device of FIG. 1, wherein the components of the baseassembly are shown exploded from one another;

FIG. 16 is a perspective view of a fastener member of the base assemblyof FIG. 14;

FIG. 17 is a perspective view of an upper sealing washer of the baseassembly of FIG. 14;

FIG. 18 is a perspective view of an upstanding base member of the baseassembly of FIG. 14;

FIG. 19 is a perspective view of a lower sealing washer of the baseassembly of FIG. 14;

FIG. 20 is a perspective view of a flashing member of the base assemblyof FIG. 14;

FIG. 21 is a perspective view of a coupling device of a photovoltaicmounting system, according to a first embodiment of the invention,wherein the coupling device is illustrated in an assembled state;

FIG. 22 is another perspective view of the coupling device of FIG. 21,wherein the components forming the coupling device are shown explodedfrom one another;

FIG. 23 is a perspective view of an upper coupling member of thecoupling device of FIG. 21;

FIG. 24 is a perspective view of a lower coupling member of the couplingdevice of FIG. 21;

FIG. 25 is a perspective view of a captive nut of the coupling device ofFIG. 21;

FIG. 26 is a perspective view illustrating the support surfaceattachment device of FIG. 1 together with the coupling device of FIG. 21and a lower skirt member connected to the support surface attachmentdevice and the coupling device;

FIG. 27 is an end view of the assembly of FIG. 26, wherein the supportsurface attachment device and lower skirt member are shown;

FIG. 28 is a perspective view of a lower skirt member, similar to thelower skirt member illustrated in FIG. 26;

FIG. 29 is a perspective view of a support surface attachment device ofa photovoltaic mounting system, according to a second embodiment of theinvention, wherein the support surface attachment device is illustratedin an assembled state;

FIG. 30 is a perspective view of an upper clamp member of the clampassembly of the support surface attachment device of FIG. 29;

FIG. 31 is a perspective view of a bonding clip of the clamp assembly ofthe support surface attachment device of FIG. 29;

FIG. 32 is a perspective view of a lower clamp member of the clampassembly of the support surface attachment device of FIG. 29;

FIG. 33 is a perspective view of a glider member of the clamp assemblyof the support surface attachment device of FIG. 29;

FIG. 34 is a perspective view of the base assembly of the supportsurface attachment device of FIG. 29, wherein the base assembly isillustrated in an assembled state;

FIG. 35 is a perspective view of an upstanding base member of the baseassembly of FIG. 34;

FIG. 36 is a perspective view of a washer of the clamp assembly of thesupport surface attachment device of FIG. 29;

FIG. 37 is a perspective view of a flashing member of the base assemblyof FIG. 34;

FIG. 38 is an end view of a lower skirt member, according to anotherembodiment of the invention;

FIG. 39 is an end view of a lower skirt member, similar to the lowerskirt member illustrated in FIG. 38, according to yet another embodimentof the invention;

FIG. 40 is a perspective view of a coupling device of a photovoltaicmounting system, according to a second embodiment of the invention,wherein the coupling device is illustrated in an assembled state;

FIG. 41 is a perspective view of an upper coupling member of thecoupling device of FIG. 40;

FIG. 42 is a perspective view of a lower coupling member of the couplingdevice of FIG. 40;

FIG. 43 is a perspective view of the clamp assembly of the supportsurface attachment device of FIG. 29, wherein the clamp assembly isillustrated in an assembled state;

FIG. 44 is an exploded view of the clamp assembly of FIG. 43;

FIG. 45 is a perspective view of an upper clamp member of the clampassembly of the support surface attachment device, according to analternative embodiment of the invention;

FIG. 46 is a side view of the upper clamp member of FIG. 46;

FIG. 47 is a perspective view of a bonding clip, according to analternative embodiment of the invention;

FIG. 48 is a perspective view of a junction box bracket attached to abase member, according to one embodiment of the invention;

FIG. 49 is a perspective view of a junction box bracket kit, accordingto another embodiment of the invention;

FIG. 50 is a perspective view of the junction box bracket of thejunction box bracket kit of FIG. 49;

FIG. 51 is a perspective view of a micro-inverter mounting plateattached to the frame of a photovoltaic module by a power accessorybracket assembly, according to an embodiment of the invention;

FIG. 52 is a perspective view of the power accessory bracket assembly ofFIG. 51, wherein the power accessory bracket assembly is in an assembledstate;

FIG. 53 is an exploded view of the power accessory bracket assembly ofFIG. 52;

FIG. 54 is a perspective view of a captive nut of the power accessorybracket assembly of FIG. 52;

FIG. 55 is a perspective view of a power accessory bracket of the poweraccessory bracket assembly of FIG. 52;

FIG. 56 is a perspective view of a threaded fastener member of the poweraccessory bracket assembly of FIG. 52;

FIG. 57 is a perspective view of a north row extension assembly,according to an embodiment of the invention;

FIG. 58 is an exploded view of the north row extension assembly of FIG.57;

FIG. 59 is a perspective view of a captive nut of the north rowextension assembly of FIG. 57;

FIG. 60 is a perspective view of an upper end clamp member of the northrow extension assembly of FIG. 57;

FIG. 61 is a perspective view of an end clamp fastener member of thenorth row extension assembly of FIG. 57;

FIG. 62 is a perspective view of a strut fastener member of the northrow extension assembly of FIG. 57;

FIG. 63 is a perspective view of a north row extension member of thenorth row extension assembly of FIG. 57;

FIG. 64 is a perspective view of an upstanding tile base member,according to an embodiment of the invention;

FIG. 65 is a perspective view of a south row mounting assembly,according to an embodiment of the invention;

FIG. 66 is an exploded view of the south row mounting assembly of FIG.65;

FIG. 67 is a perspective view of an elongated glider member of the southrow mounting assembly of FIG. 65;

FIG. 68 is a perspective view of a south row coupling assembly of aphotovoltaic mounting system, according to an embodiment of theinvention, wherein the coupling assembly is illustrated in an assembledstate;

FIG. 69 is an exploded view of the south row coupling assembly of FIG.68;

FIG. 70 is a perspective view of an upper coupling member of the southrow coupling assembly of FIG. 68;

FIG. 71 is a perspective view of an lower coupling member of the southrow coupling assembly of FIG. 68;

FIG. 72 is an end view illustrating the support surface attachmentdevice of FIG. 29 together with a lower skirt member connected to thesupport surface attachment device, according to an embodiment of theinvention;

FIG. 73 is a perspective view of a first spring member that may beutilized in the clamp assembly of FIGS. 43 and 44, according to oneembodiment of the invention;

FIG. 74 is a perspective view of a second spring member that may beutilized in the clamp assembly of FIGS. 43 and 44, according to anotherembodiment of the invention;

FIG. 75 is a side view of the upper clamp member of FIGS. 45 and 46together with a bonding clip attached thereto, according to anembodiment of the invention;

FIG. 76 is a perspective view of an upper sealing washer of the baseassembly of FIGS. 34 and 78, according to an embodiment of theinvention;

FIG. 77 is a sectional view cut through the upper sealing washer of FIG.76;

FIG. 78 is a partial sectional view cut through the base assembly ofFIG. 34, wherein sealing engagement between the base member and theflashing member is shown;

FIG. 79 is a perspective view of a junction box bracket, according toyet another embodiment of the invention;

FIG. 80 is a perspective view of the junction box bracket of FIG. 79attached to a base member;

FIG. 81 is a perspective view of a bonding clip, according to anotheralternative embodiment of the invention;

FIG. 82 is a perspective view of a north row extension assembly,according to an alternative embodiment of the invention;

FIG. 83 is an exploded view of the north row extension assembly of FIG.82;

FIG. 84 is a perspective view of a junction box bracket, according tostill another embodiment of the invention;

FIG. 85 is a perspective view of a lower coupling member of a couplingdevice, according to an alternative embodiment;

FIG. 86 is a perspective view of a conduit mounting member, according toan embodiment of the invention;

FIG. 87 is a perspective view of an upstanding tile base member,according to an alternative embodiment of the invention; and

FIG. 88 is a perspective view of the illustrative mounting systemdescribed herein being used to secure an array of photovoltaic modulesto a sloped roof.

Throughout the figures, the same parts are always denoted using the samereference characters so that, as a general rule, they will only bedescribed once.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

An first illustrative embodiment of the support surface attachmentdevice is seen generally at 100 in FIGS. 1 and 2. In one or moreembodiments, a plurality of support surface attachment devices 100 areused to securely attach an array of photovoltaic modules to a supportsurface (e.g., a sloped building roof). Referring to FIG. 2, it can beseen that support surface attachment device 100 generally comprises aclamp assembly 126 and a base assembly 128. Each of these assemblies126, 128 will be described in detail hereinafter.

Initially, with reference to FIGS. 3-13, it can be seen that theillustrative embodiment of the clamp assembly 126 generally includes anupper clamp member 10, a lower clamp member 20, and a glider member 60.As best shown in the assembled view of FIG. 3, the upper clamp member10, lower clamp member 20, and glider member 60 are connected to oneanother by means of a threaded fastener member 38 and a strut nut 72. Inthe illustrated embodiment, the threaded fastener member 38 is in theform of a bolt with a head portion having a serrated flange 40 (refer toFIG. 5). The serrations in the lower surface of the bolt head flange ofthe threaded fastener member 38 are configured to interferingly engagewith the top surface of the upper clamp member 10 (i.e., “dig into” thetop surface of the upper clamp member 10). The external threads on theshaft of the threaded fastener member 38 are configured to threadinglyengage with the internal threads 74 in the middle of the strut nut 72(see FIG. 12). As shown in FIGS. 12 and 13, the strut nut 72 hasspaced-apart elongate grooves 76 disposed in the top surface thereofthat are each configured to receive a respective downturned lip 108 ofthe base member 90, which will be described hereinafter. In addition, asbest shown in the top view of FIG. 13, it can be seen that each of theelongate grooves 76 is provided with two (2) spaced-apart protrusions orteeth 77 disposed therein. The spaced-apart teeth 77 in each groove 76are configured to interferingly engage with a bottom surface of one ofthe downturned lips 108 (i.e., “dig into” the bottom surface of one ofthe downturned lips 108). Also, referring collectively to FIGS. 12 and13, it can be seen that the strut nut 72 comprises curved sidewallportions 78 arranged diagonally opposite from one another. The curvedsidewall portions 78 allow the strut nut 72 to rotate clockwise intoposition until the flat sidewall portions contact the inside walls ofthe base member 90.

Referring again to the illustrative embodiment of FIG. 3, it can be seenthat the upper clamp member 10 and the lower clamp member 20 of clampassembly 126 cooperate to clamp one or more photovoltaic modules inplace on a support surface. That is, each photovoltaic module is clampedin place either between the first opposed flange portion 14 a of theupper clamp member 10 and the second outwardly extending ledge 28 of thelower clamp member 20 or between the second opposed flange portion 14 bof the upper clamp member 10 and the first outwardly extending ledge 26of the lower clamp member 20, depending on which side of the clampassembly 126 the photovoltaic module is disposed.

Now, with reference to FIG. 6, the structure of the upper clamp member10 will be described. As shown in this figure, the upper clamp member 10generally includes a base portion 12 that is attached to the bottomsurface of a flange portion 14 a, 14 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 12 comprises a plurality of elongate protrusions or teeth 18that are each spaced apart from one another by respective elongategrooves 19. As will be described hereinafter, the plurality of elongateprotrusions or teeth 18 matingly engage with elongate protrusions orteeth 30 disposed on the first opposed wall portion 24 a of theupstanding middle portion 22 of the lower clamp member 20. Referringagain to FIG. 6, it can be seen that the flange portion 14 a, 14 b ofthe upper clamp member 10 further comprises a fastener aperture 15 forreceiving the threaded fastener member 38 and a downwardly protrudingmember 17 that forms a back surface against which a photovoltaic modulerests when disposed in the clamp assembly 126. Also, as shown in FIG. 6,each of the flange portions 14 a, 14 b includes an elongate groove 16disposed in the bottom surface thereof. Each of the elongate grooves 16is configured to receive a trough portion 48 of a respective bondingclip 42 (see FIG. 7) that provides integrated grounding for thephotovoltaic module installation. The trough portion 48 of eachrespective bonding clip 42 is received within its respective elongategroove 16 in a press-fit or interference-fit type mounting arrangement.

The bonding or grounding clip 42, which provides integrated groundingfor the photovoltaic modules, is illustrated in FIG. 7. The bonding clip42 generally comprises a plate-like body portion with a trough portion48 extending laterally across the plate-like body portion and dividingthe plate-like body portion into two sections. In FIG. 7, it can be seenthat the plate-like body portion includes one or more upwardlyprotruding annular members 44 and one or more downwardly protrudingannular members 46. In particular, in the illustrative embodiment, theupwardly and downwardly protruding annular members 44, 46 are arrangedin an alternating sequence (i.e., a first upwardly protruding annularmember 44 followed by a downwardly protruding annular member 46, thenfollowed by a second upwardly protruding annular member 44). Theupwardly protruding members 44 are designed to pierce the metallicbottom surface of the flange portion 14 a, 14 b of the upper clampmember 10, while the downwardly protruding annular member 46 is designedto pierce the anodized layer of the photovoltaic module to provideintegrated grounding between the photovoltaic modules. To facilitateintegrated grounding between the photovoltaic modules, all of thecomponents of the support surface attachment device 100 and the couplingdevice 130 may be formed from metal.

Next, turning to FIG. 9, the structure of the lower clamp member 20 willbe explained. With reference to this figure, it can be seen that thelower clamp member 20 generally includes an upstanding middle portion 22with first and second ledge portions 26, 28 extending outwardly from theupstanding middle portion 22. In FIG. 9, it can be seen that theupstanding middle portion 22 of the lower clamp member 20 comprises alower fastener aperture 21 disposed in a bottom wall portion thereof,and an upper fastener aperture 25 disposed in a top wall portion 23thereof. Each of these apertures 21, 25 receives the shaft of thethreaded fastener member 38. The bottom wall portion and the top wallportion 23 of the upstanding middle portion 22 of the lower clamp member20 are connected to one another by first and second opposed wallportions 24 a, 24 b. As shown in FIG. 9, the first opposed wall portion24 a comprises a plurality of elongate protrusions or teeth 30 that areeach spaced apart from one another by respective elongate grooves 32. Asexplained above, the elongate teeth 30 of the first opposed wall portion24 a engage with the elongate teeth 18 of the base portion 12 of theupper clamp member 10. Referring again to FIG. 9, it can be seen thatthe second opposed wall portion 24 b comprises a plurality of elongatehook-shaped upwardly inclined protrusions or teeth 34 that are eachspaced apart from one another by respective elongate grooves 36. Thehook-shaped teeth 34 on the second opposed wall portion 24 b areconfigured to engage with a wind deflector and/or a mounting skirt fordeflecting wind up and over the photovoltaic array and/or improving theaesthetics of the array. Each of the first and second ledge portions 26,28 of the lower clamp member 20 is configured to accommodate aphotovoltaic module frame member resting thereon.

With reference to FIGS. 3, 4, and 9, it can be seen that the secondopposed ledge 28 of the lower clamp member 20 is bent slightly upward oris tapered slightly upward at an acute angle. In the installed state,the upwardly tapered ledge 28 of the lower clamp member 20 extendsuphill and slightly up and away from the building roof so as to act as aleaf spring that takes up the difference in gap between the uphill clampopening and the photovoltaic (PV) module thickness, thereby preventingthe PV module from rattling and allowing it to be secured into place. Insome embodiments, this also creates enough pressure on the upper clamplip (i.e., first opposed flange portion 14 a of upper clamp member 10)to enable a bonding point to function. Advantageously, because thesecond opposed ledge 28 of the lower clamp member 20 is provided with aslight upward taper (i.e., bowed upwardly), the lower clamp member 20applies a compressive force against the PV module when it is installedtherein. During the installation of each PV module, the PV module isinitially disposed at an upward acute angle relative to its one or moresouthern clamp assemblies 126. Then, each PV module is rotated downuntil it is generally parallel with the roof surface. As each PV moduleis rotated downwardly towards the roof surface, the edge portion of theuphill PV module presses down on the upwardly tapered ledge(s) 28 of thelower clamp member(s) 20 so as to apply a downward force on the upwardlytapered ledge 28, thereby ensuring that the PV module is securelyengaged with the lower clamp member(s) 20 and the PV module is tightlyheld in place. In response to the downward force applied by the PVmodule, the upwardly tapered ledges 28 elastically deforms or yields ina spring-like manner. As a result of the leaf spring design of theupwardly tapered ledge 28, the installer is not required to reach downover the PV module to tighten the fasteners on its one or more southernclamp assemblies 126. An attempt by the installer to tighten thefasteners on the one or more southern clamp assemblies 126 would not besafe, ergonomic, or efficient. The second ledge portion 158 of the lowercoupling member 150 may be bent slightly upward or tapered slightlyupward at an acute angle in the same manner as that described above forthe upwardly tapered ledge 28 of the lower clamp member 20 so that thecoupling device 130 is provided with the same functionality that isdescribed above for the clamp assembly 126.

In order to maintain a predetermined spacing distance between the upperand lower clamp members 10, 20, a sleeve member 50 is provided betweenthe clamp members 10, 20 (refer to FIGS. 3 and 4). That is, as bestshown in FIG. 3, the sleeve member 50 is disposed between the top wallportion 23 of the lower clamp member 20 and the bottom surface of theflange portion 14 a, 14 b of the upper clamp member 10. Turning to FIG.8, it can be seen that the sleeve member 50 of the clamp assembly 126comprises a cylindrical recess 52 extending therethrough for receivingthe shaft of the threaded fastener member 38. In an alternativeembodiment, a spring may be used rather than the sleeve member 50 tomaintain the predetermined spacing distance between the upper and lowerclamp members 10, 20.

As best shown in FIG. 3, the lower clamp member 20 is positioned above aglider member 60 that is configured to be adjustably disposed on theupstanding base member 90 in both a horizontal and vertical direction,as will be explained hereinafter. Referring to FIG. 11, it can be seenthat the glider member 60 of the clamp assembly 126 comprises agenerally inverted, U-shaped profile with a top wall portion 64 andfirst and second opposed wall portions 66 a, 66 b extending downwardlyfrom the top wall portion 64. The top wall portion 64 comprises afastener aperture 62 disposed centrally therein for receiving the shaftof the threaded fastener member 38. In FIG. 11, it can be seen that theinner surfaces of each of the first and second opposed wall portions 66a, 66 b comprises a plurality of elongate protrusions or teeth 68 thatare each spaced apart from one another by respective elongate grooves70. The set of teeth 68 on each of the inner surfaces of the opposedwall portions 66 a, 66 b are designed to engage with respective teeth110 on opposed upstanding wall portions 104 a, 104 b of the base member90. The glider member 60 may be elastically deformable such that it iscapable of snapping into place on the top of the base member 90. Topermit horizontal adjustability, the glider member 60 is capable ofbeing slid along the length of the base member 90. And, to permitvertical adjustability, the glider member 60 is capable of being movedup and down along a vertical height of the upstanding wall portions 104a, 104 b of the base member 90 and selectively engaging certain ones ofthe teeth 68, 110 with one another.

With reference to FIG. 4, it can be seen that, in the illustrativeembodiment, the clamp assembly 126 is further provided with a serratedwasher 54 disposed between the lower clamp member 20 and the glidermember 60. In FIG. 10, it can be seen that the serrated washer 54includes an annular body portion 56 with a plurality ofdiagonally-oriented teeth 58 extending radially outward from the annularbody portion 56. The diagonally-oriented teeth 58 of the serrated washer54 are designed to cut into the adjacent surfaces of the lower clampmember 20 and the glider member 60 so as resist a rotation of the lowerclamp member 20 relative to the glider member 60. The serrated washer 54with the diagonally-oriented teeth 58 is also used to electrically bondthe lower clamp member 20 to the glider member 60.

Now, referring to FIGS. 1, 2, 14, and 15, it can be seen that theillustrative embodiment of the base assembly 128 generally includes anupstanding base member 90 and a lower flashing member 118. As best shownin the assembled views of FIGS. 2 and 14, the upstanding base member 90is connected to the lower flashing member 118 by a threaded fastenermember 80. In the illustrated embodiment, the threaded fastener member80 is in the form of a structural mounting bolt with a head portion 82and a threaded shaft portion (see FIG. 16). In the illustratedembodiment, each support surface attachment device 100 is secured to arespective one of the roof rafters of a building by means of astructural mounting bolt 80 (e.g., refer to FIG. 1). In one or moreembodiments, the structural mounting bolt or screw 80 may beself-drilling so as not to require any predrilled holes in the roof.

Turning to FIG. 18, the upstanding base member 90 of the base assembly128 will now be described. As shown in this figure, the upstanding basemember 90 generally comprises a base portion with first and secondopposed base flange portions 94 a, 94 b and an elevated shelf portion98. Two opposed upstanding wall portions 104 a, 104 b extend upwardlyfrom the base portion of the base member 90. In FIG. 18, it can be seenthat each of the opposed base flange portions 94 a, 94 b comprises aplurality of fastener apertures 96 arranged in a substantially linearconfiguration along the length thereof. When it is desired to mount theupstanding base member 90 directly to the roof deck, rather than a roofrafter, the base member 90 is secured to the roof deck using fastenersdisposed in the fastener apertures 96. The base portion of the basemember 90 comprises a centrally disposed aperture 92 for accommodatingthe raised portion 122 of the flashing member 118 passing therethrough.The elevated shelf portion 98 of the base portion of the base member 90comprises a fastener aperture 102 disposed therethrough foraccommodating the shaft of the threaded fastener member 80. In FIG. 18,it can be seen that the outer surfaces of each of the first and secondopposed upstanding wall portions 104 a, 104 b comprises a plurality ofelongate protrusions or teeth 110 that are each spaced apart from oneanother by respective elongate grooves 112. As described above, the setof teeth 110 on each of the outer surfaces of the opposed wall portions104 a, 104 b are designed to engage with the respective teeth 68 on theopposed wall portions 66 a, 66 b of the glider member 60. Also, as shownin FIG. 18, the opposed wall portions 104 a, 104 b of the base member 90cooperate to define an upper elongate slot 106 that accommodates theshaft of the threaded fastener member 38 passing therethrough. Also,each of the opposed wall portions 104 a, 104 b comprises a downturnedlip portion 108 that is received within a respective one of the elongategrooves 76 disposed in the top surface of the strut nut 72.

With reference primarily to FIG. 20, the flashing member 118 of the baseassembly 128 will now be explained. The flashing member 118 helps tomaintain the integrity of the building roof by preventing roof leaks. InFIG. 20, it can be seen that the flashing member 118 generally comprisesa generally planar body portion 120 and a raised portion or projection122 that extends upwardly from the generally planar body portion 120 ina generally vertical direction. As best shown in the perspective view ofFIG. 20, the raised portion or projection 122 is offset with respect tothe center of the generally planar body portion 120 (i.e., the raisedportion or projection 122 is disposed to the side of the central pointof the generally planar body portion 120). In FIG. 20, it can be seenthat the raised portion or projection 122 includes a centrally disposedfastener aperture 124 for receiving the shaft of the structural mountingbolt 80 therein. Advantageously, the raised nature of the protrusion orprojection 122 above the remainder of the generally planar body portion120 of the flashing member 118 substantially prevents any precipitation(i.e., rain water) from entering the structure of the building roofthrough the fastener aperture 124. In the assembled state of the supportsurface attachment device 100, in order to further prevent any leaksthrough the aperture 124 of the flashing member 118, a lower sealingwasher 114 (see FIGS. 15 and 19) is provided on the top of the raisedportion or projection 122 of the flashing member 118. The lower sealingwasher 114 comprises a fastener aperture 116 disposed therein foraccommodating the shaft of the structural mounting bolt 80. The lowersealing washer 114 is sandwiched between the raised portion orprojection 122 of the flashing member 118 and the bottom surface of theelevated shelf portion 98 of the base member 90 when the base member 90is disposed on top of the flashing member 118 in the assembled state ofthe support surface attachment device 100. In addition, in the assembledstate, an upper sealing washer 84 is disposed between the bottom surfaceof the head portion 82 of the bolt 80 and the top surface of theelevated shelf portion 98 of the base member 90 to additionally preventany leaks through the roof. As shown in FIG. 17, the upper sealingwasher 84 comprises a flanged top portion 88 with a fastener aperture 86disposed through the center thereof for accommodating the shaft of thestructural mounting bolt 80. In the assembled state of the supportsurface attachment device 100, the upper sealing washer 84 is sandwichedbetween the bottom surface of the bolt head portion 82 and the topsurface of the elevated shelf portion 98 of the base member 90. In oneexemplary embodiment, the flashing member 118 may be formed from stampedmetal, and the upper and lower sealing washers 84, 114 may be formedfrom a suitable plastic or rubber, such as ethylene propylene dienemonomer (EPDM).

Advantageously, the design of the flashing member 118 illustrated inFIGS. 14, 15, and 20 results in superior waterproofing because its waterseal is elevated above the roof surface (i.e., at the top of the raisedportion or projection 122) so that the integrity of the flashingwaterproofing is maintained even if the sealing washer 114 would fail.Also, because the flashing member 118 may be formed by stamping, itsmanufacturing costs are inexpensive. In addition, the configuration ofthe flashing member 118 allows adjacent flashing members 118 to bereadily stacked for compact shipping.

Now, with reference to FIGS. 21-25, it can be seen that the illustrativeembodiment of the coupling device or assembly 130 generally includes anupper coupling member 140 secured to a lower coupling member 150. Asbest shown in the assembled view of FIG. 21 and the exploded view ofFIG. 22, the upper coupling member 140 and the lower coupling member 150are connected to one another by means of one or more threaded fastenermembers 168 (e.g., two (2) threaded fastener members 168) and one ormore respective captive nuts 170 (e.g., two (2) captive nuts 170, onefor each threaded fastener member 168). In the illustrated embodiment,each threaded fastener member 168 is in the form of a bolt with a headportion having a serrated flange (e.g., refer to FIG. 21). As describedabove for the bolts 38, the serrations in the lower surface of the bolthead flange of each threaded fastener member 168 are configured tointerferingly engage with the top surface of the upper coupling member140 (i.e., “dig into” the top surface of the upper coupling member 140).The external threads on the shaft of each threaded fastener member 168are configured to threadingly engage with the internal threads in thethreaded aperture 172 of the captive nut 170 (see FIG. 25).

Turning to FIG. 23, the structure of the upper coupling member 140 willbe described. As shown in this figure, the upper coupling member 140generally includes a base portion 142 that is attached to the bottomsurface of a flange portion 144 a, 144 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 142 comprises a plurality of elongate protrusions or teeth 148that are each spaced apart from one another by respective elongategrooves 149. As will be described hereinafter, the plurality of elongateprotrusions or teeth 148 matingly engage with elongate protrusions orteeth 160 disposed on the first opposed wall portion 154 a of theupstanding middle portion 152 of the lower coupling member 150.Referring again to FIG. 23, it can be seen that the flange portion 144a, 144 b of the upper coupling member 140 further comprises a pluralityof fastener apertures 145 for receiving respective threaded fastenermembers 168 and a downwardly protruding member 147 that forms a backsurface against which a photovoltaic module rests when disposed in thecoupling assembly 130. Also, as shown in FIG. 23, each of the flangeportions 144 a, 144 b includes an elongate groove 146 disposed in thebottom surface thereof. Each of the elongate grooves 146 is configuredto receive a trough portion 48 of a respective bonding clip 42 (seeFIGS. 7 and 22) that provides integrated grounding for the photovoltaicmodule installation. The trough portion 48 of each respective bondingclip 42 is received within its respective elongate groove 146 in apress-fit or interference-fit type mounting arrangement.

Next, turning to FIG. 24, the structure of the lower coupling member 150will be explained. With reference to this figure, it can be seen thatthe lower coupling member 150 generally includes an upstanding middleportion 152 with first and second ledge portions 156, 158 extendingoutwardly from the upstanding middle portion 152. In FIG. 24, it can beseen that the upstanding middle portion 152 of the lower coupling member150 comprises spaced-apart lower fastener apertures disposed in a bottomwall portion thereof, and spaced-apart upper fastener apertures 155disposed in a top wall portion 153 thereof. Each of these aperturesreceives a respective shaft of a respective threaded fastener member168. The bottom wall portion and the top wall portion 153 of theupstanding middle portion 152 of the lower coupling member 150 areconnected to one another by first and second opposed wall portions 154a, 154 b. As shown in FIG. 24, the first opposed wall portion 154 acomprises a plurality of elongate protrusions or teeth 160 that are eachspaced apart from one another by respective elongate grooves 162. Asexplained above, the elongate teeth 160 of the first opposed wallportion 154 a engage with the elongate teeth 148 of the base portion 142of the upper coupling member 140. Referring again to FIG. 24, it can beseen that the second opposed wall portion 154 b comprises a plurality ofelongate hook-shaped protrusions or teeth 164 that are each spaced apartfrom one another by respective elongate grooves 166. The hook-shapedteeth 164 on the second opposed wall portion 154 b are configured toengage with a wind deflector and/or a mounting skirt for deflecting windup and over the photovoltaic array and/or improving the aesthetics ofthe array, as will be described hereinafter. Each of the first andsecond ledge portions 156, 158 of the lower coupling member 150 isconfigured to accommodate a photovoltaic module frame member restingthereon.

With reference to FIGS. 26-28, a skirt member 174 of the photovoltaicmounting system will be described. Initially, referring to theperspective view of FIG. 26, it can be seen that the skirt member 174 isconfigured to be located on the southernmost edge of the array of PVmodules. The skirt member 174 is supported by spaced-apart supportsurface attachment devices 100. In particular, as shown in the side viewof FIG. 27, the skirt member 174 engages with the upper clamp member 10and the lower clamp member 20 of the clamp assembly 126 of the supportsurface attachment device 100. As shown in this figure, the skirt member174 is clampingly engaged by the upper clamp member 10, and isadditionally engaged by the hook-shaped teeth 34 of the lower clampmember 20.

Referring again to FIGS. 27 and 28, the engagement between the skirtmember 174 and the lower clamp member 20 will be explained in moredetail. As shown in the perspective view of FIG. 28, a backside of theskirt member 174 comprises a plurality of elongate hook-shapedprotrusions or teeth 176 that are each spaced apart from one another byrespective elongate grooves 178. With reference to the side view of FIG.27, it can be seen that at least some of the hook-shaped protrusions orteeth 176 of the skirt member 174 matingly engage with at least some ofthe hook-shaped protrusions or teeth 34 on the lower clamp member 20.This engagement between the hook-shaped protrusions or teeth 34, 176enables the skirt member 174 to be securely supported on the clampassembly 126. The hook-shaped protrusions or teeth 164 on the lowercoupling member 150 engage with the hook-shaped protrusions or teeth 176of the skirt member 174 in a manner that is generally the same as thatof the hook-shaped protrusions or teeth 34 on the lower clamp member 20.Advantageously, the hook-shaped protrusions or teeth 176, 34 on theskirt member 174 and the lower clamp member 20, respectively, allows theskirt member 174 to be mounted at various heights relative to the lowerclamp member 20 so that the skirt member 174 is capable of matching PVmodules having more than one height. This is important because the skirtmember 174 sets the gap size of the clamp assembly 126 and the couplingassembly 130 on the south row of the PV array to accept the first row ofPV modules.

In the perspective view of FIG. 26, it can be seen that the skirt member174 is configured to cover the exposed downhill edge of the array of PVmodules (only one skirt member 174 is shown in FIG. 26). Because theskirt member(s) 174 closes out the south row of PV modules, it improvesthe aesthetics of the completed photovoltaic array. No clamps orhardware is seen from ground. Airflow around the array is permitted. Inone exemplary embodiment, the skirt member 174 may be formed fromaluminum. In another exemplary embodiment, the skirt member 174 may beformed from a suitable polymer.

Although the invention has been shown and described with respect to acertain embodiment or embodiments, it is apparent that this inventioncan be embodied in many different forms and that many othermodifications and variations are possible without departing from thespirit and scope of this invention.’

A second illustrative embodiment of a support surface attachment deviceis seen generally at 100′ in FIG. 29. Referring to this figure, it canbe seen that, in some respects, the second illustrative embodiment issimilar to that of the first embodiment of the support surfaceattachment device 100. Moreover, some elements are common to both suchembodiments. For the sake of brevity, the elements that the secondembodiment of the support surface attachment device has in common withthe first embodiment will not be discussed in detail because thesecomponents have already been described above.

Initially, with reference to FIGS. 43 and 44, it can be seen that thesecond embodiment of the clamp assembly 126′ generally includes an upperclamp member 10′, a lower clamp member 20′, and a glider member 60′. Asbest shown in the assembled view of FIG. 43, the upper clamp member 10′,lower clamp member 20′, and glider member 60′ are connected to oneanother by means of a threaded fastener member 38 and a strut nut 72. Asin the first illustrated embodiment, the threaded fastener member 38 isin the form of a bolt with a head portion having a serrated flange 40(refer to FIG. 5). The strut nut 72 that is used in the secondillustrative embodiment is also the same as that utilized in the firstillustrative embodiment. As shown in the exploded view of FIG. 44, anO-ring 196 is provided on the shaft of the threaded fastener member 38.The O-ring 196 stabilizes the clamp assembly on the glider member 60′prior to installation.

Now, with reference to FIG. 30, the structure of the upper clamp member10′ of the second embodiment will be described. Similar to thatdescribed above for the first embodiment, the upper clamp member 10′generally includes a base portion 12′ that is attached to the bottomsurface of a flange portion 14 a, 14 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 12′ comprises a pair of elongate protrusions or teeth 18′ thatare each spaced apart from one another by an elongate groove 19′. Aswill be described hereinafter, the pair of elongate protrusions or teeth18′ matingly engage with elongate protrusions or teeth 30′ disposed onthe first opposed wall portion 24 a′ of the upstanding middle portion22′ of the lower clamp member 20′. Referring again to FIG. 30, it can beseen that the flange portion 14 a, 14 b of the upper clamp member 10′further comprises a fastener aperture 15 for receiving the threadedfastener member 38 and a downwardly protruding member 17′ that forms aback surface against which a photovoltaic module rests when disposed inthe clamp assembly 126′. Also, as shown in FIG. 30, each of the flangeportions 14 a, 14 b includes an elongate groove 16′ disposed in thebottom surface thereof. Each of the elongate grooves 16′ is configuredto receive a projection portion 49′ of a respective bonding clip 42′(see FIG. 31) that provides integrated grounding for the photovoltaicmodule installation. The projection portion 49′ of each respectivebonding clip 42′ is received within its respective elongate groove 16′in a press-fit or interference-fit type mounting arrangement. Also, asshown in FIG. 30, the upper clamp member 10′ of the clamp assemblycomprises a pair of downwardly extending lip portions 376, 378 onopposite sides of the flanged top portion 14 a, 14 b of the upper clampmember 10′. The first downwardly extending lip portion 376 is shorterthan the second downwardly extending lip portion 378 so as to facilitatethe one or more photovoltaic modules being pivotably installed into thefirst side of the clamp assembly (i.e., into the side of clamp assemblywith flange portion 14 a). As such, the shorter downwardly extending lipportion 376 does not interfere with the minimum gap needed to allowpivoted north side PV module mounting.

A third illustrative embodiment of the upper clamp member 10″ is shownin FIGS. 45 and 46. The third embodiment of the upper clamp member 10″is similar in most respects to the second embodiment of the upper clampmember 10′ explained above. Like the second embodiment of the upperclamp member 10′, the upper clamp member 10″ in FIGS. 45 and 46generally includes a base portion 12″ that is attached to the bottomsurface of a flange portion 14 a, 14 b at approximately a 90 degreeangle. Although, in FIGS. 45 and 46, it can be seen that the one side ofthe base portion 12″ of the upper clamp member 10″ comprises three (3)elongate protrusions or teeth 18′ that are each spaced apart from oneanother by respective elongate grooves 19″, rather than the pair ofelongate protrusions or teeth 18′ described above for the secondembodiment. Similar to the upper clamp member 10′ of FIG. 30, each ofthe flange portions 14 a, 14 b of the upper clamp member 10″ of FIGS. 45and 46 includes an elongate groove 16″ disposed in the bottom surfacethereof for accommodating a respective bonding clip (e.g., bonding clip42′ in FIG. 31 or bonding clip 42″ in FIG. 47). However, unlike theupper clamp member 10′ of FIG. 30, the downwardly protruding member 17″of the upper clamp member 10″ additionally contains a groove 11 formedin one side thereof for capturing an edge of the bonding clip (e.g.,bonding clip 42′ in FIG. 31 or bonding clip 42″ in FIG. 47), and holdingit in place (refer to FIG. 75).

Additional embodiments of the bonding or grounding clip, which providesintegrated grounding for the photovoltaic modules, are illustrated inFIGS. 31, 47, and 81, respectively. Similar to the bonding clip 42 ofFIG. 7 described above, the bonding clips 42′, 42″ of FIGS. 31 and 47each comprise a plate-like body portion with a plurality of upwardlyprotruding annular members 44′ and a plurality of downwardly protrudingannular members 46′ formed therein. In particular, in the illustrativeembodiments, each of the upwardly protruding annular members 44′ isarranged adjacent to a respective opposite end of the plate-like bodyportion, and the pair of downwardly protruding annular members 46′ aredisposed between the pair of upwardly protruding annular members 44′.The upwardly and downwardly protruding annular members 44′, 46′ are alsogenerally arranged in a staggered, non-aligned configuration on theplate-like body portions of the bonding clips 42′, 42″. As explainedabove for bonding clip 42, the upwardly protruding members 44 aredesigned to pierce the metallic bottom surface of the flange portion 14a, 14 b of the upper clamp member 10′, while the downwardly protrudingannular member 46 is designed to pierce the anodized layer of thephotovoltaic module to provide integrated grounding between thephotovoltaic modules.

Referring to bonding clip 42′ in FIG. 31, it can be seen that aprojection portion 49 is attached to the plate-like body portion of thebonding clip 42′. The projection portion 49 of the bonding clip 42′engages with a selected one of the elongate grooves 16′, 16″ in theupper clamp members 10′, 10″ so as to hold the bonding clip 42′ inplace. The bonding clip 42″ of FIG. 47 also contains a projectionportion 49′ that is attached to the plate-like body portion of thebonding clip 42″. As shown in FIG. 47, the projection portion 49′ of thebonding clip 42″ comprises a pair of spaced-apart bent over tabs 47,47′, wherein each tab 47, 47′ is disposed at an opposite end of theprojection portion 49′. Each of the tabs 47, 47′ engages with a selectedone of the elongate grooves 16′, 16″ in the upper clamp members 10′, 10″in order to hold the bonding clip 42′, 42″ in place in the clampassembly 126′. Also, similar to the bonding clips 42, 42′, 42″, thebonding clip 42′″ of FIG. 81 comprises a plate-like body portion 43 witha plurality of upwardly protruding annular members 44′ and a pluralityof downwardly protruding annular members 46′ formed therein. Theplate-like body portion 43 of the clip 42′″ is not folded over. Like theembodiment of FIGS. 31 and 47, the upwardly and downwardly protrudingannular members 44′, 46′ of the clip 42′″ are arranged in a staggeredconfiguration. However, unlike the preceding embodiments of the bondingclip, the clip attachment portions of the bonding clip 42′″ of FIG. 81comprise a pair of flange members 45, each of which is disposed at anopposite end of the clip body portion 43. When the bonding clip 42′″ isinstalled on an object (e.g., upper clamp members 10′, 10″), a topportion of each of the pair of flange members 45 (i.e., the top fold ofthe flange members 45) remains visible to an installer so that aninstalled condition of the bonding clip 42′″ is capable of beingverified by the installer. Also, advantageously, the flange members 45of the bonding clip 42′″ allow the clip 42′″ to be installed without theneed to fully open the clamp assembly (i.e., the installer only needs toopen the clamp a small amount). In one or more embodiments, the bondingclip 42′″ may be used on the north side of a photovoltaic module row.

Next, turning to FIG. 32, the structure of the second embodiment of thelower clamp member 20′ will be explained. Similar to that describedabove for the lower clamp member 20, it can be seen that the lower clampmember 20′ generally includes an upstanding middle portion 22′ withfirst and second ledge portions 26, 28 extending outwardly from theupstanding middle portion 22′ (refer to FIG. 32). In FIG. 32, it can beseen that the upstanding middle portion 22 of the lower clamp member 20comprises a lower fastener aperture 21 disposed in a bottom wall portionthereof, and an upper fastener aperture 25 disposed in a top wallportion 23′ thereof. Each of these apertures 21, 25 receives the shaftof the threaded fastener member 38. The bottom wall portion and the topwall portion 23′ of the upstanding middle portion 22 of the lower clampmember 20 are connected to one another by first and second opposed wallportions 24 a′, 24 b′. As shown in FIG. 32, the first opposed wallportion 24 a′ comprises a plurality of elongate protrusions or teeth 30′(e.g., with generally wedge-shaped cross-sections) that are each spacedapart from one another by respective elongate grooves 32′. As explainedabove, the elongate teeth 30′ of the first opposed wall portion 24 a′engage with the elongate teeth 18′ of the base portion 12′ of the upperclamp member 10′. Referring again to FIG. 32, it can be seen that thesecond opposed wall portion 24 b′ comprises a plurality of upwardlyinclined elongate protrusions or teeth 34′ that are spaced apart fromone another by elongate grooves 36′, 37. More particularly, the uppertwo (2) protrusions or teeth 34′ are spaced apart from one another bythe narrow width elongate groove 36′, while the upper two (2)protrusions or teeth 34′ are spaced apart from a bottom protrusion ortooth 34′ disposed near the surface of the second ledge portion 28 by awide elongate groove 37. The upwardly inclined elongate protrusions orteeth 34′ on the second opposed wall portion 24 b′ are configured toengage with a wind deflector and/or a mounting skirt for deflecting windup and over the photovoltaic array and/or improving the aesthetics ofthe array (see e.g., FIG. 72). Advantageously, the upwardly inclinedelongate protrusions or teeth 34′ allow the skirt to be dropped in atthe appropriate height, and once the skirt is secured, the upward facingprotrusions or teeth 34′ resist torsional detachment from the lowerclamp member 20′ (e.g., due to ice expansion on the PV array applying aforce against the skirt). Each of the first and second ledge portions26, 28 of the lower clamp member 20 is configured to accommodate aphotovoltaic module frame member resting thereon. As described above forthe first embodiment of the lower clamp member 20, the second opposedledge 28 of the lower clamp member 20′ is bent slightly upward, or istapered slightly upward at an acute angle, so as to be capable ofperforming the same functionality explained above for the lower clampmember 20. In addition, as shown in FIG. 32, the lower clamp member 20′of the clamp assembly comprises a plurality of ridges 380 disposed on abottom surface thereof. The ridges 380 are configured to increase africtional engagement between the lower clamp member 20′ and the glidermember 60′ so as prevent the upper and lower clamp members 10′, 20′ ofthe clamp assembly from rotating relative to the glider member 60′ whenthe threaded fastener member 38 is tightened by an installer (i.e., theridges 380 increase the resistance to rotation of the clamp assembly onthe glider member 60′).

In the illustrated embodiment, one or more of the teeth or serrations30′ on the lower clamp member 20′ are configured to engage one or moreof the teeth or serrations 18′ on the upper clamp member 10′ when thethreaded fastener 38 is being tightened so as to maintain a minimum gapbetween the upper clamp member 10′ and the lower clamp member 20′ forreceiving one or more photovoltaic module frames of one or morephotovoltaic modules when the one or more photovoltaic modules arepivotably installed into a first side (e.g., north side) of the clampassembly. In an exemplary embodiment, the clamp assembly 10′, 20′ isdesigned to accept 32, 33, 35, 40, 45, and 50 millimeter (mm) PVmodules. As such, in the exemplary embodiment, the serrations 18′, 30′on the upper and lower clamp members 10′, 20′ are positioned to engageat the above mentioned dimensions. As the threaded fastener 38 of theclamp is tightened, the downhill side of the clamp contacts a module(e.g., the south side of the clamp), and a torque is applied to theupper clamp member 10′ engaging the teeth. This allows the uphill sideof the clamp (e.g., the north side of the clamp), to remain open,allowing the next module to slide in from above, and to be pivotedmounted in place.

In order to maintain a predetermined spacing distance between the upperand lower clamp members 10′, 20′ during PV module installation, a leafspring member 186 is provided between the clamp members 10′, 20′ (referto FIGS. 43 and 44). In an exemplary embodiment, the leaf spring member186 may be Z-shaped. That is, as best shown in FIG. 43, the leaf springmember 186 is disposed between the top wall portion 23′ of the lowerclamp member 20′ and the bottom surface of the flange portion 14 a, 14 bof the upper clamp member 10′. During the installation of the PV modulesin the PV array, the spring member 186 holds the upper clamp member 10′in place above the lower clamp member 20′ so that a PV module can beinserted between the two (2) clamp members 10′, 20′. Without the use ofthe spring member 186, the flange 14 a, 14 b of the upper clamp member10′ would tend to just rest on the top of the lower clamp member 20′,thereby making it very difficult to insert between the two (2) clampmembers 10′, 20′. In addition, the use of the spring member 186 in theclamp assembly 126′ allows the fastener member 38 to be tightened sothat the strut nut 72 engages the base and secures the clamp to the base90′ without the clamp being compressed.

Turning to FIG. 73, it can be seen that the leaf spring member 186 ofthe clamp assembly 126′ comprises bottom and top leg portions 188, 192,which are connected to one another by a middle diagonal leg portion 190.Each of the leg portions 188, 190, 192 is provided with a respectivefastener aperture 194 disposed therethrough for accommodating the shaftof the threaded fastener member 38. An alternative embodiment of theleaf spring member 186′ is depicted in FIG. 74. Like the spring member186, the leaf spring member 186′ of FIG. 74 comprises bottom and top legportions 188′, 192′, which are connected to one another by a middlediagonal leg portion 190′. However, it can be seen that the geometry ofthe leg portions 188′, 190′, 192′ of the spring member 186′ of FIG. 74are slightly different than the leg portions 188, 190, 192 of the springmember 186 (e.g., the outer ends of the bottom and top leg portions188′, 192′ are not bent like the bottom and top leg portions 188, 192 ofthe FIG. 73 embodiment). Also, similar to the spring member 186, each ofthe leg portions 188, 190, 192 of the spring member 186′ in FIG. 74 isprovided with a respective fastener aperture 194′ disposed therethroughfor accommodating the shaft of the threaded fastener member 38. However,it can be seen that the fastener apertures 194′ are generallyoval-shaped, rather than being circular as in FIG. 73.

As best shown in FIG. 43, the lower clamp member 20′ is positioned abovea glider member 60′ that is configured to be adjustably disposed on theupstanding base member 90′ in both a horizontal and vertical direction,similar to that explained above for the glider member 60. Referring toFIG. 33, like the glider member 60 described above, it can be seen thatthe glider member 60′ of the clamp assembly 126′ comprises a generallyinverted, U-shaped profile with a top wall portion 64′ and first andsecond opposed wall portions 66 a′, 66 b′ extending downwardly from thetop wall portion 64′. The top wall portion 64′ comprises a fasteneraperture 62 disposed centrally therein for receiving the shaft of thethreaded fastener member 38. In FIG. 33, it can be seen that the innersurfaces of each of the first and second opposed wall portions 66 a′, 66b′ comprises a pair of elongate protrusions or teeth 68′ that are spacedapart from one another by a respective elongate groove 70′. The pair ofteeth 68′ on each of the inner surfaces of the opposed wall portions 66a′, 66 b′ are designed to engage with respective teeth 110 on opposedupstanding wall portions 104 a′, 104 b′ of the base member 90′. Theglider member 60′ may be slid into place on the top of the base member90′ by engaging its teeth 68′ with the teeth 110 of the base member 90′.To permit horizontal adjustability, the glider member 60′ is capable ofbeing slid along the length of the base member 90′. And, to permitvertical adjustability, the glider member 60′ is capable of beingadjusted placed along a vertical height of the upstanding wall portions104 a′, 104 b′ of the base member 90′ by selectively engaging certainones of the teeth 68′ on the glider member 60′ with certain ones of thegrooves 112 on the base member 90′, and the groove 70′ on the glidermember 60′ with a certain one of the teeth 110 on the base member 90′.

As shown in FIG. 33, the outer sides of the first and second opposedwall portions 66 a′, 66 b′ of the glider member 60′ are provided with aplurality of generally parallel, visual indicator grooves 61 formedtherein (e.g., three (3) visual indicator grooves 61). During theinstallation of the PV modules, the visual indicator grooves 61 operateas visual indicating bands for positioning the clamp assembly 126′ atits desired height (i.e., the visual indicator grooves 61 enable thedesired height of the clamp assembly 126′ relative to the base member90′ to be more easily obtained by the installer during the PV moduleinstallation process). Also, referring again to FIG. 33, it can be seenthat opposed protrusions 63 may be provided at the top of the glidermember 60′ for holding a chalk line (e.g., a string) in place that isused for the alignment of the PV module row on the support surface(e.g., roof). In an illustrative embodiment, the chalk line (e.g., astring) may be received within the topmost one of the grooves 61, andthe lower two (2) grooves 61 may be used as visual aid indicatorsshowing the height of the glider member 60′ on the upstanding basemember 90′ (i.e., corresponding to the grooves 61).

Now, referring to FIGS. 29 and 34, it can be seen that the secondillustrative embodiment of the base assembly 128′ generally includes anupstanding base member 90′ and a lower flashing member 118′. As bestshown in the assembled view of FIG. 34, the upstanding base member 90′is connected to the lower flashing member 118′ by a threaded fastenermember 80. As described above for the first illustrated embodiment, thethreaded fastener member 80 of the second embodiment is in the form of astructural mounting bolt with a head portion 82 and a threaded shaftportion (see FIG. 16). In the illustrated embodiment, each supportsurface attachment device 100′ is secured to a respective one of theroof rafters of a building by means of a structural mounting bolt 80(e.g., refer to FIG. 29).

Turning to FIG. 35, the upstanding base member 90′ of the base assembly128′ will now be described. As shown in this figure, the upstanding basemember 90′ generally comprises a base portion with first and secondopposed base flange portions 94 a, 94 b and an elevated shelf portion98′. Unlike the first embodiment of the upstanding base member 90′, theelevated shelf portion 98′ of the upstanding base member 90′ does notcomprise any recesses formed therein. Rather, the elevated shelf portion98′ is a generally planar plate that extends between the two (2) opposedupstanding wall portions 104 a′, 104 b′. In FIG. 35, it can be seen thatthe opposed upstanding wall portions 104 a′, 104 b′ extend upwardly fromthe base portion of the base member 90′. Also, with reference to FIG.35, it can be seen that each of the opposed base flange portions 94 a,94 b comprises a plurality of fastener apertures 96 arranged in asubstantially linear configuration along the length thereof. When it isdesired to mount the upstanding base member 90′ directly to the roofdeck, rather than a roof rafter, the base member 90′ is secured to theroof deck using fasteners disposed in the fastener apertures 96. Thebase portion of the base member 90′ comprises a centrally disposedaperture 92 for accommodating the raised portion 122′ of the flashingmember 118′ passing therethrough. The elevated shelf portion 98′ of thebase portion of the base member 90′ comprises a flashing/fasteneraperture 102 disposed therethrough for accommodating the top annularportion 125 of the flashing raised portion 122′ and the shaft of thethreaded fastener member 80 disposed within the flashing annular portion125 (e.g., see the sectional view in FIG. 78). In FIG. 35, it can beseen that the outer surfaces of each of the first and second opposedupstanding wall portions 104 a, 104 b comprises a plurality of elongateprotrusions or teeth 110 that are each spaced apart from one another byrespective elongate grooves 112. As described above, the set of teeth110 on each of the outer surfaces of the opposed wall portions 104 a,104 b are designed to engage with the respective teeth 68′ on theopposed wall portions 66 a′, 66 b′ of the glider member 60′. Also, asshown in FIG. 35, the opposed wall portions 104 a′, 104 b′ of the basemember 90′ cooperate to define an upper elongate slot 106 thataccommodates the shaft of the threaded fastener member 38 passingtherethrough. Also, each of the opposed wall portions 104 a′, 104 b′comprises a downturned lip portion 108 that is received within arespective one of the elongate grooves 76 disposed in the top surface ofthe strut nut 72. Turning to FIG. 34, it can be seen that a bottomsurface of the upstanding base member 90′ may include a plurality ofridges 382 disposed thereon. The ridges 382 are configured to increase africtional engagement between the upstanding base member 90′ and theflashing member 118′ so as prevent the upstanding base member 90′ fromrotating relative to the flashing member 118′ when a base fastenermember 80 is tightened by an installer (i.e., the ridges 382 slightlydeform the flashing member 118′ when the base member 90′ is tightenedagainst the flashing so as to resist the turning of the base member 90′relative to the flashing member 118′). Also, the ridges 382 disposed onthe bottom surface of the upstanding base member 90′ are additionallyconfigured to capture and hold sealing tape (e.g., butyl tape) when theupstanding base member 90′ is mounted directly against the supportsurface (e.g., directly against a roof deck in deck-mountedinstallation). Referring again to FIG. 34, it can be seen that a topsurface of the upstanding base member 90′ may include a plurality ofvisual installation guide marks 384 configured to facilitate aninstallation of one or more rows of the one or more photovoltaic modules(e.g., to facilitate the accurate setting of the south row in the PVmodule array).

With reference primarily to FIG. 37, the flashing member 118′ of thebase assembly 128′ will now be explained Like the flashing member 118described above, the flashing member 118′ helps to maintain theintegrity of the building roof by preventing roof leaks. In FIG. 37, itcan be seen that the flashing member 118′ generally comprises agenerally planar body portion 120′ and a raised portion or projection122′ that extends upwardly from the generally planar body portion 120′in a generally vertical direction. As best shown in the perspective viewof FIG. 37, the raised portion or projection 122′ is offset with respectto the center of the generally planar body portion 120′ (i.e., theraised portion or projection 122′ is disposed to the side of the centralpoint of the generally planar body portion 120′). In FIG. 37, it can beseen that the raised portion or projection 122′ includes a centrallydisposed fastener aperture 124 for receiving the shaft of the structuralmounting bolt 80 therein. As shown in FIG. 37, the flashing raisedportion 122′ further includes a generally horizontal ledge portion 123that extends radially inward towards the fastener aperture 124, andannular collar portion 125 that extends upwardly from the ledge portion123 of the flashing raised portion 122′. As shown in the sectional viewof FIG. 78, the bottom surface of the elevated shelf portion 98′ of thebase member 90′ is disposed adjacent to the flashing ledge portion 123in the assembled state of the base assembly 128′, while the upstanding,annular collar portion 125 of the flashing raised portion 122′ extendsthrough the flashing/fastener aperture 102 in the base shelf portion 98′to help maintain the integrity of the building roof. As described abovefor the flashing member 118, the raised nature of the protrusion orprojection 122′ above the remainder of the generally planar body portion120′ of the flashing member 118′ substantially prevents anyprecipitation (i.e., rain water) from entering the structure of thebuilding roof through the fastener aperture 124. In the assembled stateof the support surface attachment device 100′, in order to furtherprevent any leaks through the aperture 124 of the flashing member 118′,an upper sealing washer 84′ (see FIGS. 76-78) is provided on the top ofthe annular collar portion 125 of the flashing raised portion 122′ ofthe flashing member 118′.

In the illustrated embodiment of FIG. 78, when the upstanding basemember 90′ of the base assembly is assembled with the flashing member118′, a top surface of the circumferential ledge portion 123 of theraised portion 122′ of the flashing member 118′ is configured toregulate a height of the top annular portion 125 of the raised portion122′ of the flashing member 118′ so that a top rim of the top annularportion 125 of the raised portion 122′ does not protrude substantiallyabove a top surface of the elevated shelf 98′ of the upstanding basemember 90′. That is, in the illustrative embodiment, when the basemember 90′ contacts the flashing member 118′, the top annular portion125 protrudes a small predetermined distance above the top surface ofthe elevated shelf 98′. The interface between the base member 90′and theflashing member 118′dictates the height of the flashing protruding abovethe base web or shelf 98′, and it prevents the over compression of thesealing member 89 of the sealing washer 84′. The large radius at thebase of the raised portion 122′ of the flashing member 118′ is designedto flex to accommodate various roof conditions further increasing theuniformity of sealing interface.

With combined reference to FIGS. 76-78, it can be seen that the uppersealing washer 84′ comprises a fastener aperture 86 disposedtherethrough for accommodating the shaft of the structural mounting bolt80. The upper sealing washer 84′ is disposed between the bottom surfaceof the head portion 82 of the bolt 80 and the top surface of theelevated shelf portion 98′ of the base member 90′ to additionallyprevent any leaks through the roof. As shown in FIGS. 76-78, the uppersealing washer 84′ comprises a top outer portion 87 and a bottom innerportion 89 disposed within, and underneath the top outer portion 87. Inone exemplary embodiment, the top outer portion 87 of the upper sealingwasher 84′ may be formed from stainless steel and the bottom innerportion 89 of the upper sealing washer 84′ may be formed from a suitableplastic or rubber, such as ethylene propylene diene monomer (EPDM). Inone or more embodiments, the upper sealing washer 84′ is a cup washerthat is configured to control the type and/or amount of washercompression so that, when compressed by the tightening of the bolt 80,the EPDM inner portion 89 of the washer 84′ will not enter into theannular gap between the outer surface of the flashing annular collarportion 125 and the inner circular wall of the flashing/fasteneraperture 102 in the base shelf portion 98′ of the base member 90′. Thatis, the compression of the upper sealing washer 84′ is regulated so asto seal around the outer sidewall of the flashing annular collar portion125, but not enter the annular gap between the flashing annular collarportion 125 and the inner circular wall of the flashing/fasteneraperture 102, thereby creating an efficient waterproof seal for the baseassembly 128′.

As best shown in the illustrative embodiment of FIG. 77, the bottominner portion 89 of the upper sealing washer 84′ may comprise a steppedand/or upwardly tapered bottom surface 85 so as to tightly engage thetop rim of the flashing annular collar portion 125, and to prevent theEPDM inner portion 89 of the washer 84′ from entering the fasteneraperture 124 in the flashing member 118′ (see FIGS. 37 and 78).

Advantageously, the design of the flashing member 118′ illustrated inFIGS. 34, 37, and 78 results in superior waterproofing because its waterseal is elevated above the roof surface (i.e., at the top of the raisedportion or projection 122′) so that the integrity of the flashingwaterproofing is maintained. Also, because the flashing member 118′ maybe formed by stamping, its manufacturing costs are inexpensive. Inaddition, the configuration of the flashing member 118′ allows adjacentflashing members 118′ to be readily stacked for compact shipping.

With reference to FIG. 36, in the illustrative embodiment, the baseassembly 128′ may be further provided with a serrated washer 54′disposed between the ledge portion 123 of the flashing raised portion122′ and the bottom surface of the elevated shelf portion 98′ of thebase member 90′ when the base member 90′ is disposed on top of theflashing member 118′ in the assembled state of the support surfaceattachment device 100′. The serrated washer 54′ is used for electricallygrounding the base assembly 128′ by creating a current path between thebase member 90′ and the flashing member 118′. In FIG. 36, it can be seenthat the serrated washer 54′ includes an outer annular body portion 56′with a plurality of diagonally-oriented teeth 58′ extending radiallyinward from the outer annular body portion 56′. The diagonally-orientedteeth 58′ of the serrated washer 54′ are designed to cut into theadjacent surfaces of the base member 90′ and the flashing member 118′ soas to provide an electrical grounding path between the two components sothat the two components are electrically bonded to one another.

Now, with reference to FIGS. 40-42, it can be seen that, like thecoupling assembly 130 described above, the second illustrativeembodiment of the coupling assembly 130′ generally includes an uppercoupling member 140′ secured to a lower coupling member 150′. As bestshown in the assembled view of FIG. 40, the upper coupling member 140′and the lower coupling member 150′ are connected to one another by meansof one or more threaded fastener members 168 (e.g., two (2) threadedfastener members 168) and one or more respective captive nuts 170 (e.g.,two (2) captive nuts 170, one for each threaded fastener member 168). Inthe illustrated embodiment, each threaded fastener member 168 is in theform of a bolt with a head portion having a serrated flange (e.g., referto FIG. 40).

Turning to FIG. 41, the structure of the upper coupling member 140′ willbe described. As shown in this figure, the upper coupling member 140′generally includes a base portion 142′ that is attached to the bottomsurface of a flange portion 144 a, 144 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 142′ comprises a plurality of elongate protrusions or teeth 148′that are each spaced apart from one another by respective elongategrooves 149′. As will be described hereinafter, the plurality ofelongate protrusions or teeth 148′ matingly engage with elongateprotrusions or teeth 160′ disposed on the first opposed wall portion 154a′ of the upstanding middle portion 152′ of the lower coupling member150′. Referring again to FIG. 41, it can be seen that the flange portion144 a, 144 b of the upper coupling member 140 further comprises aplurality of fastener apertures 143, 145 for receiving respectivethreaded fastener members 168 and a downwardly protruding member 147′that forms a back surface against which a photovoltaic module rests whendisposed in the coupling assembly 130. In the illustrative embodiment ofFIG. 41, it can be seen that each of fastener apertures 143 has agenerally oval shape, while the fastener apertures 145 has a generallycircular shape. Also, as shown in FIG. 41, each of the flange portions144 a, 144 b includes an elongate groove 146′ disposed in the bottomsurface thereof. Each of the elongate grooves 146′ is configured toreceive one or more projection portions 49, 49′ of the bonding clip 42′,42″ that provides integrated grounding for the photovoltaic moduleinstallation. The projection portion 49, 49′ of each bonding clip 42′,42″ is received within its respective elongate groove 146′ in apress-fit or interference-fit type mounting arrangement. Turning to FIG.41, it can be seen that a top surface of flanged portion 144 a, 144 b ofthe upper coupling member 140′ may include a plurality of visualinstallation guide marks 386 to indicate locational limits of mountingthe one or more photovoltaic modules within the coupling device 130′(i.e., location limits of mounting against the PV modules).

Next, turning to FIG. 42, the structure of the lower coupling member150′ will be explained. With reference to this figure, it can be seenthat the lower coupling member 150′ generally includes an upstandingmiddle portion 152′ with first and second ledge portions 156, 158extending outwardly from the upstanding middle portion 152′. In FIG. 42,it can be seen that the upstanding middle portion 152′ of the lowercoupling member 150′ comprises spaced-apart lower fastener aperturesdisposed in a bottom wall portion thereof, and spaced-apart upperfastener apertures 155 disposed in a top wall portion 153′ thereof. Eachof these apertures receives a respective shaft of a respective threadedfastener member 168. The bottom wall portion and the top wall portion153′ of the upstanding middle portion 152′ of the lower coupling member150′ are connected to one another by first and second opposed wallportions 154 a′, 154 b′. As shown in FIG. 42, the first opposed wallportion 154 a′ comprises a plurality of elongate protrusions or teeth160′ that are each spaced apart from one another by respective elongategrooves 162′. As explained above, the elongate teeth 160′ of the firstopposed wall portion 154 a′ engage with the elongate teeth 148′ of thebase portion 142′ of the upper coupling member 140′. Referring again toFIG. 42, it can be seen that the second opposed wall portion 154 b′comprises a plurality of elongate upwardly inclined protrusions or teeth164′, one or more elongate downwardly inclined protrusions or teeth 165,and one or more elongate V-shaped protrusions or teeth 167. As shown inFIG. 42, the protrusions or teeth 164′, 165, 167 are spaced apart fromone another by elongate grooves 166′. The protrusions or teeth 164′,165, 167 on the second opposed wall portion 154 b′ of the base portion142′ of the lower coupling member 150′ are configured to engage with awind deflector and/or a mounting skirt for deflecting wind up and overthe photovoltaic array and/or improving the aesthetics of the array, aswill be described hereinafter. Each of the first and second ledgeportions 156, 158 of the lower coupling member 150 is configured toaccommodate a photovoltaic module frame member resting thereon. As shownin FIG. 42, the protrusions or teeth 164′, 165, 167 of the lowercoupling member 150′ comprise a plurality of mating protrusions or teeth164′, 165, 167 disposed in alternating upward and downward orientationsso that the coupling device 130′ is capable of remaining in engagementwith the skirt member 174″ prior to the threaded fastening members 168being tightened by an installer. For example, in one or moreembodiments, the coupling device 130′ is initially slid on the skirtmember 174″ by the installer, and once slid on, the coupling device 130′will stay in place and the installer can take his or her hand off thecoupling device 130′. The alternating protrusions or teeth 164′, 165,167 of the lower coupling member 150′ allow the coupling device 130′ tostay in place on the skirt member 174″.

In the illustrated embodiment, one or more of the teeth or serrations160′ on the lower coupling member 150′ are configured to engage one ormore of the teeth or serrations 148′ on the upper coupling member 140′when the threaded fasteners 168 are being tightened so as to maintain aminimum gap between the upper coupling member 140′ and the lowercoupling member 150′ for receiving one or more photovoltaic moduleframes of one or more photovoltaic modules when the one or morephotovoltaic modules are pivotably installed into a first side (e.g.,north side) of the coupling assembly 130′. In an exemplary embodiment,the coupling assembly 130′ is designed to accept 32, 33, 35, 40, 45, and50 millimeter (mm) PV modules. As such, in the exemplary embodiment, theserrations 148′, 160′ on the upper and lower coupling members 140′,150′are positioned to engage at the above mentioned dimensions. As thethreaded fasteners 168 of the coupling are tightened, the downhill sideof the coupling contacts a module (e.g., the south side of thecoupling), and a torque is applied to the upper coupling member 140′engaging the teeth. This allows the uphill side of the coupling (e.g.,the north side of the coupling), to remain open, allowing the nextmodule to slide in from above, and to be pivoted mounted in place.

With reference to FIGS. 38, 39, and 72, additional embodiments of thelower skirt member 174′, 174″ of the photovoltaic mounting system willbe described. Initially, referring to the end view of FIG. 72, it can beseen that the skirt member 174′, 174″ is configured to be located on thesouthernmost edge of the array of PV modules. The skirt member 174′,174″ is supported by spaced-apart support surface attachment devices100′. In particular, as shown in the end view of FIG. 72, the skirtmember 174″ engages with the upper clamp member 10′ and the lower clampmember 20′ of the clamp assembly 126′ of the support surface attachmentdevice 100′. As shown in this figure, the skirt member 174″ isclampingly engaged by the upper clamp member 10′, and is additionallyengaged by the teeth 34′ of the lower clamp member 20′ (e.g., on thesouth side of the clamp). FIG. 72 also illustrates the photovoltaicmodule frame 372 of the photovoltaic module 374 engaged with the side ofthe clamp assembly 10′, 20′ that is opposite to the side on which theskirt member 174″ is engaged (e.g., the north side).

Now, with reference to FIG. 85, an alternative of a lower couplingmember 150″ will be described. The lower coupling member 150″ of FIG. 85is similar in most respects to the lower coupling member 150′ of FIG. 42explained above. Although, unlike the lower coupling member 150′, thefirst and second ledge portions 156′, 158′ of the lower coupling member150″ are provided with respective drainage troughs 157, 159 formedtherein for draining water from one or more photovoltaic modules thatincorporate a module drainage feature.

Referring again to FIGS. 39 and 72, the engagement between the skirtmember 174″ and the lower clamp member 20′ will be explained in moredetail. As shown in the end view of FIG. 39, a backside of the skirtmember 174″ comprises a plurality of downwardly-directed protrusions orteeth 176′ and one or more upwardly-directed protrusions or teeth 180that are spaced apart from one another by elongate grooves or gaps 178′,184. More particularly, the upper two (2) protrusions or teeth 176′ arespaced apart from one another by the narrow width elongate groove 178′,while the pair of upper protrusions or teeth 176′ are spaced apart fromupwardly-directed protrusion or tooth 180 by a wide elongate groove orgap 184. With reference to the end view of FIG. 72, it can be seen thatat least some of the protrusions or teeth 176′, 180 of the skirt member174″ matingly engage with at least some of the protrusions or teeth 34′on the lower clamp member 20′. This engagement between the protrusionsor teeth 34′, 176′, 180 enables the skirt member 174″ to be securelysupported on the clamp assembly 126′. The protrusions or teeth 164′ onthe lower coupling member 150′ engage with the protrusions or teeth176′, 180 of the skirt member 174″' in a manner that is generally thesame as that of the protrusions or teeth 34′ on the lower clamp member20′. Advantageously, the protrusions or teeth 176′, 180, 34′ on theskirt member 174″ and the lower clamp member 20′, respectively, allowsthe skirt member 174″ to be mounted at various heights relative to thelower clamp member 20′ so that the skirt member 174′ is capable ofmatching the height of many different PV modules. This is importantbecause then the skirt member 174″ sets the gap size of the clampassembly 126′ and the coupling assembly 130′ on the south row of the PVarray to accept the first row of PV modules.

Another embodiment of the skirt member 174′ is illustrated in FIG. 38.The skirt member 174′ of FIG. 38 is similar in many respects to theskirt member 174″ of FIG. 39 that was described above. However, unlikethe skirt member 174″, the skirt member 174′ of FIG. 38 additionallycomprises a V-shaped protrusions or tooth 182 disposed on the backsideof the skirt member 174′. As shown in this figure, the V-shapedprotrusions or tooth 182 is disposed between the bottommostdownwardly-directed protrusion or tooth 176′ and the upwardly-directedprotrusion or tooth 180. The skirt member 174′ of FIG. 38 is designed tobe used with a PV array comprising PV modules with specific heights,while the skirt member 174″ of FIG. 39 is designed to be used with a PVarray comprised of PV modules of different heights. Advantageously, theupwardly-directed protrusions or teeth 34′ on the lower clamp member20′, and the downwardly-directed protrusion or teeth 176′ on the skirtmembers 174′, 174″, allow the skirt members 174′, 174″ to be droppedinto the clamp assemblies 126′ from the side, thereby greatlyfacilitating the installation of the PV array by obviating the need toslide the skirt members 174′, 174″ into the clamp assemblies 126′ fromthe end of the PV array. The skirt members 174′, 174″ are able to beslid into the coupling assemblies 130 without difficulty during theinstallation of the PV array.

Now, with reference to FIGS. 48-71 79, and 80, various accessories ofthe sloped roof solar panel mounting system will be described.Initially, turning to FIGS. 48-50, the junction box bracket 198, 198′will be explained. In the PV array, the junction box bracket 198, 198′holds a junction box where PV module wires terminate at the end of thearray. The junction box bracket 198, 198′ may be provided withpre-drilled holes or self-drilling/self-tapping screws may be used. Afirst embodiment of the junction box bracket 198 is shown in FIG. 48. InFIG. 48, it can be seen that the junction box bracket 198 comprises abase portion 200 and a flange portion 202, which is disposed atapproximately a ninety (90) degree angle relative to the base portion200. The flange portion 202 of the junction box bracket 198 is attachedto the base member 90′ by a plurality of fasteners 210. To facilitatethe installation of the junction box bracket 198, the fasteners 210 maybe self-drilling and/or self-tapping type fasteners (i.e.,self-drilling/self-tapping bolts or screws).

Like the first embodiment of the junction box bracket 198, the secondembodiment of the junction box bracket 198′ illustrated in FIGS. 49 and50 also comprises a base portion 200′ and a flange portion 202′ that isoriented at a substantially ninety (90) degree angle relative to thebase portion 200′. However, as shown in these two figures, the baseportion 200′ of the junction box bracket 198′ may be predrilled with aplurality of apertures 204 for mounting the junction box thereto. Also,the flange portion 202′ of the junction box bracket 198′ may bepredrilled with a plurality of apertures 206 disposed along the lengththereof for securing the junction box bracket 198′ to the base member90′. In addition, as shown in FIG. 49, the junction box bracket 198′ maybe provided with prepackaged fasteners 208 for mounting the junction boxto the junction box bracket 198′ and/or for mounting the junction boxbracket 198′ to the base member 90′.

A third embodiment of the junction box bracket is illustrated in FIGS.79 and 80. Unlike the junction box brackets 198, 198′ of FIGS. 48-50,the junction box bracket 340 in FIGS. 79 and 80 is in the form of acenter-mounted junction box bracket. That is, the junction box bracket340 is configured to be center-mounted on the base member 90′. In FIGS.79 and 80, it can be seen that the junction box bracket 340 generallycomprises a plate-like base portion 342, a first flange portion 344, anda second flange portion 346 spaced apart from the first flange portion344. The first and second flange portions 344, 346 extend from one sideof the plate-like base portion 342 of the junction box bracket 340, andtogether define a slot for receiving a cross-sectional portion of thebase portion 90′ therein. As shown in these two figures, the plate-likebase portion 342 of the junction box bracket 340 comprises a pluralityof apertures 348 and a plurality of elongate slots 350 disposedtherethrough for attaching a wide variety of different junction boxes tothe junction box bracket 340. Also, the first and second flange portions344, 346 of the junction box bracket 340 may be predrilled with aplurality of apertures 352 disposed therethrough for accommodatingfasteners that secure the junction box bracket 340 to the base member90′. The aperture 352 mounted in the horizontal portion of the secondflange portion 346 in FIGS. 79 and 80 may be used for mounting agrounding lug.

A fourth embodiment of the junction box bracket is illustrated in FIG.84. Unlike the junction box bracket 340 of FIGS. 79 and 80, the junctionbox bracket 340′ in FIG. 84 is in the form of an offset-mounted junctionbox bracket. That is, the first and second flange portions 344′, 346′ ofthe junction box bracket 340′ are offset from a center position of thebracket base portion 342 in a widthwise direction of the bracket baseportion 342 so as to facilitate a connection of one or more wires to thejunction box (or other electrical accessory mounted on the bracket baseportion 342) without the upstanding base member 90′ of the base assembly128′ interfering with a routing of the one or more wires.

Next, with reference to FIGS. 51-56, the power accessory bracket 212will be described. As shown in the perspective view of FIG. 51, thepower accessory bracket 212 is used to mount a power accessory (such asa micro-inverter or optimizer) to the aluminum frame 226 of thephotovoltaic (PV) module. The teeth 214 on the underside of the poweraccessory bracket 212 electrically connect the bracket to the aluminumframe 226 of the PV module (see FIGS. 51 and 52). With combinedreference to FIGS. 51, 52, and 53, it can be seen that themicro-inverter mounting plate 224 is attached to the power accessorybracket 212 by means of a threaded fastener 218 (e.g., a bolt) and acaptive nut 220 that threadingly engages with the fastener 218. As shownin FIG. 54, the captive nut 220 has a threaded aperture 222 thatreceives the shaft of the threaded fastener 218. During the assembly ofthe components, the captive nut 220 is pressed into the central aperture216 of the power accessory bracket 212. In FIG. 56, it can be seen thatthreaded fastener 218, like the threaded fastener member 38 describedabove, is provided with a head portion having a serrated flange 219 forelectrical grounding/bonding purposes.

Turning to FIGS. 57-63, the north row extension assembly 250 of the PVarray mounting system will be explained. Initially, with reference toFIGS. 57 and 58, it can be seen that the illustrative embodiment of thenorth row extension assembly 250 generally includes a north rowextension member 230 and an upper end clamp member 252. As best shown inthe assembled view of FIG. 57, the upper end clamp member 252 and thenorth row extension member 230 are connected to one another by means ofa threaded fastener member 270 and a captive nut 228. Similar to thethreaded fastener member 38 described above, the threaded fastenermember 270 is in the form of a bolt with a head portion having aserrated flange 272 (refer to FIG. 61). As shown in FIG. 59, the captivenut 228 has a threaded aperture 229 that receives the shaft of thethreaded fastener 270. The north row extension assembly 250 attaches toa base member 90′ of the PV array mounting system by means of a pair ofthreaded fastener members 264 that threadingly engage with respectivestrut nuts 72. A pair of threaded fastener members 264 and correspondingstrut nuts 72 are used for securing the north row extension assembly 250to the base member 90′, rather than just a single threaded fastenermember 264 and strut nut 72, in order to provide added stability. Likethe end clamp threaded fastener 270, the threaded fastener member 264 ofthe illustrative embodiment is in the form of a bolt with a head portionhaving a serrated flange 266 (refer to FIG. 62). Also, as shown in FIG.62, the top surface of the head portion of the threaded fastener member264 is provided with a visual indicator line 268 formed therein forindicating the orientation of the strut nut 72 that is threadinglyengaged with the threaded fastener member 264. The north row extensionassembly 250 is used when a clamp located at or near the peak of theroof is desired and it would be difficult or not possible to install aflashing at that location because there are not enough shingle coursesup-roof of the location to allow the flashing to be installed. As aresult, the flashing member 118′ is required to be placed under ashingle course that is two courses down from the peak of the roof. Thenorth row extension assembly 250 operates as a cantilevered mounting armfor securing the north row edge of the PV module array.

Now, with reference primarily to FIG. 63, the structure of the north rowextension member 230 of the north row extension assembly 250 will bedescribed. As shown in FIG. 63, like the glider member 60′ describedabove, it can be seen that the north row extension member 230 comprisesa generally inverted, U-shaped profile with a top wall portion 236 andfirst and second opposed wall portions 238, 240 extending downwardlyfrom the top wall portion 236. The top wall portion 236 comprises aplurality of spaced-apart fastener apertures 234 disposed near a firstlongitudinal end thereof for receiving the strut nut fastener members264 described above, and a single fastener aperture 242 disposed nearthe second, opposite longitudinal end thereof for receiving the endclamp fastener 270. The plurality of spaced-apart fastener strutapertures 234 advantageously permits the locations of the strut nutfastener members 264 to be adjusted. In FIG. 63, it can be seen that theinner surfaces of each of the first and second opposed wall portions238, 240 comprises a pair of elongate protrusions or teeth 244 that arespaced apart from one another by a respective elongate groove 246. Thepair of teeth 244 on each of the inner surfaces of the opposed wallportions 238, 240 are designed to engage with respective teeth 110 onopposed upstanding wall portions 104 a′, 104 b′ of the base member 90′.The north row extension member 230 may be slid into place on the top ofthe base member 90′ by engaging its teeth 244 with the teeth 110 of thebase member 90′. To permit horizontal adjustability, the north rowextension member 230 is capable of being slid along the length of thebase member 90′. And, to permit vertical adjustability, the north rowextension member 230 is capable of being adjustably placed along avertical height of the upstanding wall portions 104 a′, 104 b′ of thebase member 90′ by selectively engaging certain ones of the teeth 244 onthe north row extension member 230 with certain ones of the grooves 112on the base member 90′, and the groove 246 on the north row extensionmember 230 with a certain one of the teeth 110 on the base member 90′.

As best shown in FIG. 63, the outer sides of the first and secondopposed wall portions 238, 240 of the north row extension member 230 areprovided with a plurality of generally parallel, visual indicatorgrooves 232 formed therein (e.g., three (3) visual indicator grooves232). During the installation of the PV modules, the visual indicatorgrooves 232 operate as visual indicating bands for positioning the northrow extension member 230 at its desired height (i.e., the visualindicator grooves 232 enable the desired height of the north rowextension member 230 relative to the base member 90′ to be more easilyobtained by the installer during the PV module installation process).

Next, turning to FIG. 60, the structure of the upper end clamp member252 will be explained. The upper end clamp member 252 secures the northedge of the PV module in the PV array. As shown in this figure, theupper end clamp member 252 generally includes a vertical body portion254 that is attached to a horizontal flange portion 260 at approximatelya 90 degree angle. In this figure, it can be seen that vertical bodyportion 254 of the upper end clamp member 252 has an offset 256 formedtherein. Referring again to FIG. 60, it can be seen that the flangeportion 260 of the upper end clamp member 252 further comprises afastener aperture 258 for receiving the threaded fastener member 270.Also, as shown in FIG. 60, the flange portion 260 includes an elongategroove 262 disposed in the bottom surface thereof. The elongate groove262 of the upper end clamp member 252 is configured to receive aprojection portion 49′ of a respective bonding clip 42″ (see FIG. 58)that provides integrated grounding for the photovoltaic moduleinstallation. The projection portion 49′ of the bonding clip 42″ isreceived within the elongate groove 262 of upper end clamp member 252 ina press-fit or interference-fit type mounting arrangement.

Turning to FIGS. 82 and 83, an alternative embodiment of the north rowextension assembly 250′ of the PV array mounting system will bedescribed. The north row extension assembly 250′ of FIGS. 82 and 83 issimilar in many respect to the north row extension assembly 250explained above. However, unlike the north row extension assembly 250 ofFIG. 57, the north row extension assembly 250′ utilizes a clamp assemblycomprising the upper clamp member 10 and the lower clamp member 20′described above, rather than the upper end clamp member 252. In asimilar manner to that described above for the support surfaceattachment device 100′, the clamp members 10, 20′ are used to secure oneor more photovoltaic modules to the north row extension assembly 250′.Turning again to FIGS. 82 and 83, it can be seen that the north rowextension member 230′ of the north row extension assembly 250′ isslightly different that the north row extension member 230 describedabove. For example, the north row extension member 230′ contains agreater number of spaced-apart fastener apertures 234 than the north rowextension member 230, and the north row extension member 230′ containsan elongated slot 242′ for receiving the clamp fastener 270′, ratherthan a circular aperture 242. Rather than being provided with thecaptive nut 228 at the distal end thereof, the clamp fastener 270′ isprovided with a modified strut nut 227 for securing the clamp assemblyto the north row extension member 230′.

Referring to the exploded view of FIG. 58, the O-ring member 248 of thenorth row extension assembly 250 is used to maintain a predeterminedspacing distance or gap between the flange portion 260 of the upper endclamp member 252 and the top wall portion 236 of the north row extensionmember 230. In other words, the O-ring member 248 is used to hold upperend clamp member 252 open so that a PV module may be more easilyinserted between the flange portion 260 of the upper end clamp member252 and the top wall portion 236 of the north row extension member 230during the installation of the PV module array on the roof.

An embodiment of an upstanding tile base member 274 is illustrated inFIG. 64. The upstanding tile base member 274 of FIG. 64 is configured tobe attached to a PV tile mounting solution (such as a tile replacementbracket or a tile hook). The tile base member 274 is capable of beingused in any location within the array. Referring to FIG. 64, it can beseen that the upstanding tile base member 274 generally comprises a baseportion 276 and a pair of opposed first and second upstanding wallportions 278, 280 extending upwardly from the base portion 276 of theupstanding tile base member 274. In FIG. 64, it can be seen that theouter surfaces of each of the first and second opposed upstanding wallportions 278, 280 comprises a plurality of elongate protrusions or teeth286 that are each spaced apart from one another by respective elongategrooves 288. The set of teeth 286 on each of the outer surfaces of theopposed wall portions are designed to engage with the respective teeth68′ on the opposed wall portions 66 a′, 66 b′ of the glider member 60′.Also, as shown in FIG. 64, the opposed wall portions 278, 280 of theupstanding tile base member 274 cooperate to define an upper elongateslot 282 that accommodates the shaft of the threaded fastener member 38passing therethrough. Also, each of the opposed wall portions 278, 280comprises a downturned lip portion 284 that is received within arespective one of the elongate grooves 76 disposed in the top surface ofthe strut nut 72.

An alternative embodiment of the upstanding tile base member is shown inFIG. 87. The upstanding tile base member 274′ of FIG. 87 is similar inmost respects to the upstanding tile base member 274 described above.However, as shown in FIG. 87, the upstanding tile base member 274′ has alonger profile length as compared to the base member 274 of FIG. 64.

Turning to FIGS. 65-67, the south row mounting assembly 290 of the PVarray mounting system will be explained. Initially, with reference toFIGS. 65 and 66, it can be seen that the illustrative embodiment of thesouth row mounting assembly 290 generally includes an elongated glidermember 292 and an upper end clamp member 252. As best shown in theassembled view of FIG. 65 and the exploded view of FIG. 66, the upperend clamp member 252 and the elongated glider member 292 are connectedto one another by means of a threaded fastener member 270 and a captivenut 228. The south row mounting assembly 290 attaches to a base member90′ of the PV array mounting system by means of a threaded fastenermember 264 that threadingly engages with a strut nut 72. The south rowmounting assembly 290 may be used on the south edge of the PV modulearray in lieu of the double clamp assembly 126′ and the skirt member174′, 174″. From an aesthetic standpoint, the south row mountingassembly 290 may be used as an alternative to the skirt member 174′,174″.

Now, with reference primarily to FIG. 67, the structure of the elongatedglider member 292 of the south row mounting assembly 290 will bedescribed. As shown in FIG. 67, like the glider member 60′ describedabove, it can be seen that the elongated glider member 292 comprises agenerally inverted, U-shaped profile with a top wall portion 298 andfirst and second opposed wall portions 300, 302 extending downwardlyfrom the top wall portion 298. The top wall portion 236 comprises afirst fastener aperture 296 disposed near a first longitudinal endthereof for receiving the strut nut fastener member 264 described above,and a second fastener aperture 304 disposed near the second, oppositelongitudinal end thereof for receiving the end clamp fastener 270. InFIG. 67, it can be seen that the inner surfaces of each of the first andsecond opposed wall portions 300, 302 comprises a pair of elongateprotrusions or teeth 306 that are spaced apart from one another by arespective elongate groove 308. The pair of teeth 306 on each of theinner surfaces of the opposed wall portions 300, 302 are designed toengage with respective teeth 110 on opposed upstanding wall portions 104a′, 104 b′ of the base member 90′. The elongated glider member 292 maybe slid into place on the top of the base member 90′ by engaging itsteeth 306 with the teeth 110 of the base member 90′. To permithorizontal adjustability, the elongated glider member 292 is capable ofbeing slid along the length of the base member 90′. And, to permitvertical adjustability, the elongated glider member 292 is capable ofbeing adjustably placed along a vertical height of the upstanding wallportions 104 a′, 104 b′ of the base member 90′ by selectively engagingcertain ones of the teeth 306 on the elongated glider member 292 withcertain ones of the grooves 112 on the base member 90′, and the groove308 on the elongated glider member 292 with a certain one of the teeth110 on the base member 90′.

As best shown in FIG. 67, the outer sides of the first and secondopposed wall portions 300, 302 of the elongated glider member 292 areprovided with a plurality of generally parallel, visual indicatorgrooves 294 formed therein (e.g., three (3) visual indicator grooves294). During the installation of the PV modules, the visual indicatorgrooves 294 operate as visual indicating bands for positioning the southrow mounting assembly 290 at its desired height (i.e., the visualindicator grooves 294 enable the desired height of the south rowmounting assembly 290 relative to the base member 90′ to be more easilyobtained by the installer during the PV module installation process).Because the upper end clamp member 252 of the south row mountingassembly 290 is generally the same as that described above for the northrow extension assembly 250, in the interest of brevity, it will not bedescribed again in conjunction with the south row mounting assembly 290.

Referring to the exploded view of FIG. 66, the O-ring member 248 of thesouth row mounting assembly 290 performs the same functionality asdescribed above for the north row extension assembly 250. That is, theO-ring member 248 is used to hold upper end clamp member 252 open sothat a PV module may be more easily inserted between the flange portion260 of the upper end clamp member 252 and the top wall portion 298 ofthe south row mounting assembly 290 during the installation of the PVmodule array on the roof.

Next, referring to FIGS. 68-71, the south row, single-sided couplingassembly 310 of the PV array mounting system will be explained. Similarto the coupling assemblies 130, 130′ described above, south row couplingassembly 310 generally includes an upper coupling member 312 secured toa lower coupling member 324. As best shown in the assembled view of FIG.68, the upper coupling member 312 and the lower coupling member 324 areconnected to one another by means of one or more threaded fastenermembers 168 (e.g., two (2) threaded fastener members 168) and one ormore respective captive nuts 170 (e.g., two (2) captive nuts 170, onefor each threaded fastener member 168). In the illustrated embodiment,each threaded fastener member 168 is in the form of a bolt with a headportion having a serrated flange (e.g., refer to FIG. 68). The south rowcoupling assembly 310 may be used on the south edge of the PV modulearray when the south row mounting assembly 290 is used in lieu ofproviding the skirt member 174′, 174″ on the south row. As shown inFIGS. 70 and 71, unlike the coupling assembly 130′ described above, theupper and lower coupling members 312, 324 of the skirtless couplingassembly 310 do not comprise any mating teeth or protrusions disposedthereon.

Turning to FIG. 70, the structure of the upper coupling member 312 ofthe south row coupling assembly 310 will be described. As shown in thisfigure, the upper coupling member 312 generally includes a vertical bodyportion 314 that is attached to a horizontal flange portion 316 atapproximately a 90 degree angle. Referring again to FIG. 70, it can beseen that the flange portion 316 of the upper coupling member 312further comprises a plurality of fastener apertures 318, 320 forreceiving respective threaded fastener members 168. In the illustrativeembodiment of FIG. 70, it can be seen that the first fastener aperture318 has a generally oval shape, while the second fastener aperture 320has a generally circular shape. Also, as shown in FIG. 70, the flangeportion 316 includes an elongate groove 322 disposed in the bottomsurface thereof. The elongate groove 316 is configured to receive one ormore projection portions 49, 49′ of the bonding clip 42′, 42″ thatprovides integrated grounding for the photovoltaic module installation(see e.g., FIG. 69). The projection portion 49, 49′ of the bonding clip42′, 42″ is received within the elongate groove 316 in a press-fit orinterference-fit type mounting arrangement.

Next, turning to FIG. 72, the structure of the lower coupling member 324of the south row coupling assembly 310 will be explained. With referenceto this figure, it can be seen that the lower coupling member 324generally includes an upstanding portion 326 with a ledge portion 336extending outwardly from one side of the upstanding portion 326. In FIG.71, it can be seen that the upstanding portion 326 of the lower couplingmember 324 comprises spaced-apart threaded fastener apertures 334disposed therethrough. Each of these apertures 334 receives a respectiveshaft of a respective threaded fastener member 168. The upstandingportion 326 of the lower coupling member 324 further comprises a topwall portion 328 and first and second opposed wall portions 330, 332extending downwardly from the top wall portion 328. The ledge portion336 of the lower coupling member 324 is configured to accommodate aphotovoltaic module frame member resting thereon (i.e., a frame memberof a south row PV module).

Referring to the exploded view of FIG. 69, the O-ring member 248 of thesouth row coupling assembly 310 performs generally the samefunctionality as described above for the north row extension assembly250 and the south row mounting assembly 290. That is, the O-ring member248 is used to hold upper coupling member 312 open so that a PV modulemay be more easily inserted between the flange portion 316 of the uppercoupling member 312 and the ledge portion 336 of the lower couplingmember 324 during the installation of the PV module array on the roof.

Now, turning to FIG. 86, an illustrative embodiment of a conduitmounting member 360 will be described. The conduit mounting member 360is configured to couple electrical conduit of a photovoltaic system toan upstanding base member 90′ of a base assembly 128′. The conduitmounting member 360 is configured to mount a conduit strap or otherconduit holding device such that conduit of a photovoltaic system can bemounted to the conduit mounting member 360. As shown in FIG. 86, theconduit mounting member 360 includes a generally vertical securementportion 362 comprising a plurality of spaced-apart mounting apertures364 for attaching the conduit mounting member 360 to the upstanding basemember 90′ (e.g., by using one or more tek screws). The conduit mountingmember 360 further comprises a generally horizontal conduit mountingportion 366 connected to the generally vertical securement portion 362.The conduit mounting portion 366 comprises a plurality of spaced-apartsecurement apertures 368 for attaching the electrical conduit to theconduit mounting member 360 (e.g., by using a conduit strap). As shownin the illustrative embodiment of FIG. 86, the conduit mounting member360 resembles the shape of angle iron flange, wherein the generallyvertical securement portion 362 is disposed generally transverselyrelative to the horizontal conduit mounting portion 366.

Turning to FIG. 88, an illustrative photovoltaic system 400 utilizingthe constituent mounting system components described herein is shown.FIG. 88 illustrates a roof-mounted photovoltaic (PV) system or arrayaccording to an embodiment of the present invention. The illustratedphotovoltaic system or array includes an array of solar panels or PVmodules 374 mounted to a pitched or sloped support surface in the formof a building rooftop 370 by a mounting system. For clarity ofillustration of the mounting components, the photovoltaic module frames372 are primarily shown in FIG. 88 rather than the full modules 374,with one exemplary full PV module 374 illustrated in the south row. InFIG. 88, there are three (3) rows of PV modules 374 illustrated forexemplary purposes, each of the first two rows having three (3) PVmodules 374 disposed therein, and the third row (i.e., the north row)having only one PV modules 374 disposed therein. The illustratedmounting system includes a plurality of support surface attachmentdevices 100′ that secure the photovoltaic module frames 372 to thebuilding rooftop 370. The PV array illustrated in FIG. 88 has each ofthe rectangular-shaped PV modules 374 oriented in a landscapeorientation, that is, with the longest axis of the PV modules extendingin a lateral or side-to-side direction which is typically the east-westdirection. It is noted, however, that the PV modules can alternativelybe oriented by the support surface attachment devices 100′ in a portraitorientation, that is, with the longest axis of the PV modules extendingin a forward-rearward direction which is typically the south-northdirection. With reference again to FIG. 88, it can be seen that theillustrated mounting system also includes a plurality of couplingdevices 130′ that rigidly fasten a plurality of PV modules 374 to oneanother. As shown in FIG. 88, the coupling devices 130′ connect thecorners of adjacent PV modules 374 together. Also, an exemplary sectionof a skirt member 174″ is depicted on the south edge of the PV array inFIG. 88. On the north edge of the PV array in FIG. 88, north rowextension assemblies 250′ are shown supporting the north side of aphotovoltaic module frame 372 in a cantilevered manner. As explainedabove, the north row extension assemblies 250′ advantageously allows anadditional north row of PV modules to be installed in the array at ornear the ridge/peak of the 370 where support surface attachment devices100′ are unable to be accommodated on the north sides of the PV modules(e.g., because shingle courses are unable to be loosened in roof ridgearea). Referring again to FIG. 88, it can be seen that a junction boxbracket 340′ is mounted to the upstanding base member 90′ of the supportsurface attachment devices 100′ of the leftmost PV module in the secondrow of the PV module array to support a junction box or other electricalaccessory of the photovoltaic system.

Any of the features or attributes of the above described embodiments andvariations can be used in combination with any of the other features andattributes of the above described embodiments and variations as desired.

Moreover, while exemplary embodiments have been described herein, one ofordinary skill in the art will readily appreciate that the exemplaryembodiments set forth above are merely illustrative in nature and shouldnot be construed as to limit the claims in any manner. Rather, the scopeof the invention is defined only by the appended claims and theirequivalents, and not, by the preceding description.

The invention claimed is:
 1. A support surface attachment device, saidsupport surface attachment device configured to attach one or morephotovoltaic modules to a support surface, said support surfaceattachment device comprising: a base assembly configured to be attachedto a support surface; and a clamp assembly configured to engage one ormore photovoltaic modules, said clamp assembly including a lower clampmember and an upper clamp member, said upper clamp member connected tosaid lower clamp member by a fastener member, said lower clamp memberincluding one or more first teeth disposed thereon, and said upper clampmember including one or more second teeth disposed thereon, said one ormore first teeth on said lower clamp member configured to engage saidone or more second teeth on said upper clamp member when said fasteneris being tightened so as to maintain a minimum gap between said upperclamp member and said lower clamp member for receiving one or morephotovoltaic module frames of said one or more photovoltaic modules whensaid one or more photovoltaic modules are pivotably installed into afirst side of said clamp assembly; and wherein said clamp assembly iscapable of being selectively positioned along a length of said baseassembly prior to being fixed in place relative to said base assembly soas to permit adjustability when said one or more photovoltaic modulesare being attached to said support surface.
 2. The support surfaceattachment device according to claim 1, wherein said upper clamp memberof said clamp assembly comprises one or more grooves for receiving aportion of a bonding clip for grounding said one or more photovoltaicmodules.
 3. The support surface attachment device according to claim 1,further comprising a spring member disposed between said upper clampmember and said lower clamp member of said clamp assembly, said springmember configured to hold said clamp assembly open for facilitating theinstallation of said one or more photovoltaic modules into said clampassembly, and said spring member further configured to enable said clampassembly to be secured on said base assembly while maintaining saidminimum gap between said upper clamp member and said lower clamp member.4. The support surface attachment device according to claim 1, furthercomprising a strut nut threadingly coupled to said fastener member, saidstrut nut configured to fix said clamp assembly in place relative tosaid base assembly when said fastener member is tightened.
 5. Thesupport surface attachment device according to claim 4, wherein saidfastener member comprises a visual indicator line formed on a headportion of said fastener member for indicating an orientation of saidstrut nut.
 6. The support surface attachment device according to claim1, further comprising a glider member coupling said upper and lowerclamp members of said clamp assembly to said base assembly, said glidermember configured to slide relative to said base assembly so as to allowsaid clamp assembly to be selectively positioned along said length ofsaid base assembly prior to being fixed in place relative to said baseassembly.
 7. The support surface attachment device according to claim 6,wherein said glider member comprises one or more protrusions or groovesformed in an outer side of said glider member, said one or moreprotrusions or grooves configured to serve as a visual indicatorindicating a height of said clamp assembly relative to said baseassembly and/or serve as a means for holding a chalk line during aninstallation of said one or more photovoltaic modules.
 8. The supportsurface attachment device according to claim 6, wherein said upper andlower clamp members of said clamp assembly are configured to rotatetogether relative to said glider member, and wherein an upstanding basemember of said base assembly is configured to rotate relative to saidsupport surface, whereby the rotation of said upper and lower clampmembers relative to said glider member and the rotation of saidupstanding base member of said base assembly relative to a flashingmember of said support surface attachment device enables a lateralposition of said clamp assembly to be adjusted by an installer.
 9. Thesupport surface attachment device according to claim 6, wherein saidlower clamp member of said clamp assembly comprises one or more ridgesdisposed on a bottom surface of said lower clamp member, said one ormore ridges configured to increase a frictional engagement between saidlower clamp member and said glider member so as resist said upper andlower clamp members of said clamp assembly from rotating relative tosaid glider member when said fastener member is tightened by aninstaller.
 10. The support surface attachment device according to claim6, wherein said base assembly includes an upstanding base member, saidupstanding base member comprising one or more mating grooves and one ormore mating protrusions for engaging with one or more mating protrusionsand one or more mating grooves of said glider member, wherein a selectedengagement between said one or more mating grooves and protrusions ofsaid upstanding base member and said one or more mating grooves andprotrusions of said glider member enables said clamp assembly to beselectively positioned at a predetermined height relative to said baseassembly prior to being fixed in place relative to said base assembly soas to permit vertical adjustability when said one or more photovoltaicmodules are being attached to said support surface.
 11. The supportsurface attachment device according to claim 1, wherein said upper clampmember of said clamp assembly comprises a first downwardly protrudingmember and a second downwardly protruding member spaced apart from saidfirst downwardly protruding member by a gap, said second downwardlyprotruding member being shorter in length than said first downwardlyprotruding member, and said second downwardly protruding memberconfigured to provide an abutment surface for a skirt member.
 12. Thesupport surface attachment device according to claim 1, wherein saidlower clamp member of said clamp assembly comprises one or more matinggrooves and one or more mating protrusions for engaging with one or moremating protrusions and one or more mating grooves of a skirt member. 13.The support surface attachment device according to claim 12, whereinsaid one or more mating protrusions on said lower clamp member areupwardly inclined so as to enable said skirt member to be inserted intosaid clamp assembly from above during installation, and so as to preventsaid skirt member from becoming disengaged from said clamp assemblyafter said installation of said skirt member.
 14. The support surfaceattachment device according to claim 1, wherein said upper clamp memberof said clamp assembly comprises a pair of downwardly extending lipportions on opposite sides of a top portion of said upper clamp member,a first one of said pair of downwardly extending lip portions beinglonger than a second one of said pair of downwardly extending lipportions so as to facilitate said one or more photovoltaic modules beingpivotably installed into said first side of said clamp assembly.
 15. Thesupport surface attachment device according to claim 1, wherein saidlower clamp member of said clamp assembly comprises an upwardly taperedledge extending outwardly from said first side of said clamp assembly,said upwardly tapered ledge configured to support said one or morephotovoltaic module frames of said one or more photovoltaic modules, andsaid upwardly tapered ledge being configured to function as a spring forapplying a compressive force against said one or more photovoltaicmodule frames of said one or more photovoltaic modules so as to securelyretain said one or more photovoltaic modules in said clamp assemblyafter said one or more photovoltaic modules are pivotably installed. 16.The support surface attachment device according to claim 1, wherein saidbase assembly includes an upstanding base member, said upstanding basemember including a pair of vertically spaced-apart bottom wall portions,a first of said pair of vertically spaced-apart bottom wall portionscomprising a first aperture and a second of said pair of verticallyspaced-apart bottom wall portions comprising a second aperture, saidfirst and second apertures of said upstanding base member configured toreceive a raised portion of a flashing member therein so as to permit afastener aperture disposed in said flashing member to be elevated abovesaid support surface, thereby enabling said support surface attachmentdevice to be more leakage resistant.
 17. The support surface attachmentdevice according to claim 16, wherein said upstanding base member ofsaid base assembly further comprises one or more base flange portions,said one or more base flange portions having one or more mountingapertures disposed therethrough, said one or more mounting aperturesconfigured to receive one or more respective fasteners for securing saidupstanding base member to said support surface.
 18. The support surfaceattachment device according to claim 16, wherein a bottom surface ofsaid upstanding base member comprises one or more ridges disposedthereon, said one or more ridges configured to increase a frictionalengagement between said upstanding base member and said flashing memberso as prevent said upstanding base member from rotating relative to saidflashing member when a base fastener member is tightened by aninstaller.
 19. The support surface attachment device according to claim18, wherein said one or more ridges disposed on said bottom surface ofsaid upstanding base member are additionally configured to capture andhold sealing tape when said upstanding base member is mounted directlyagainst said support surface.
 20. The support surface attachment deviceaccording to claim 16, wherein a top surface of said upstanding basemember comprises one or more visual installation guide marks configuredto facilitate an installation of one or more rows of said one or morephotovoltaic modules.
 21. The support surface attachment deviceaccording to claim 1, further comprising a flashing member having afastener aperture configured to receive a base fastener member forattaching an upstanding base member of said base assembly and saidflashing member to said support surface, said fastener aperture beingdisposed through a raised position of said flashing member so that wateris prevented from passing through said fastener aperture.
 22. Thesupport surface attachment device according to claim 21, furthercomprising a sealing washer configured to be disposed between a head ofsaid base fastener member and a top rim of said raised position of saidflashing member, said sealing washer including an upper portion formedfrom a first material and a lower portion formed from a second material,said first material forming said upper portion of said sealing washerrestricting a deformation of said second material forming said lowerportion of said sealing washer so as to prevent said sealing washer fromentering said fastener aperture in said flashing member.
 23. The supportsurface attachment device according to claim 22, wherein said lowerportion of said sealing washer further comprises a tapered bottomsurface so as to tightly engage said top rim of said raised portion ofsaid flashing member and to prevent said second material forming saidlower portion of said sealing washer from entering said fasteneraperture in said flashing member.
 24. The support surface attachmentdevice according to claim 21, wherein said raised portion of saidflashing member comprises a circumferential ledge portion, wherein, whensaid upstanding base member of said base assembly is assembled with saidflashing member, a top surface of said circumferential ledge portion ofsaid raised portion of said flashing member is configured to regulate aheight of an upper section of said raised portion of said flashingmember that is disposed above said circumferential ledge portion so thata top rim of said upper section of said raised portion does not protrudesubstantially above a top surface of an elevated shelf of saidupstanding base member.
 25. The support surface attachment deviceaccording to claim 1, further comprising a cantilevered mounting armcoupling said clamp assembly to said base assembly, said cantileveredmounting arm configured to support said clamp assembly in a cantileveredmanner from said base assembly so that said clamp assembly is capable ofbeing horizontally offset from said base assembly, thereby allowing oneor more edges of said one or more photovoltaic modules to be disposedabove a region of said support surface that is unable to accommodatesaid base assembly.
 26. The support surface attachment device accordingto claim 25, wherein said region of said support surface that is unableto accommodate said base assembly comprises an area at or near a roofridge, and wherein said cantilevered mounting arm enables one or moreadditional photovoltaic modules to be installed proximate to said roofridge.
 27. The support surface attachment device according to claim 1,further comprising an electrical accessory bracket configured to mountan electrical accessory of a photovoltaic system to an upstanding basemember of said base assembly, said electrical accessory bracketcomprising at least one flange portion configured to attach saidelectrical accessory bracket to said upstanding base member, saidelectrical accessory bracket further comprising a bracket base portioncomprising one or more mounting apertures for attaching said electricalaccessory to said electrical accessory bracket.
 28. The support surfaceattachment device according to claim 27, wherein said at least oneflange portion of said electrical accessory bracket is offset from acenter position of said bracket base portion in a widthwise direction ofsaid bracket base portion so as to facilitate a connection of one ormore wires to said electrical accessory without said upstanding basemember of said base assembly interfering with a routing of said one ormore wires.
 29. The support surface attachment device according to claim27, wherein said bracket base portion of said electrical accessorybracket comprises a plurality of slots formed therein for accommodatingvarious electrical accessories, and wherein said at least one flangeportion of said electrical accessory bracket comprises at least oneaperture formed therein for accommodating a grounding lug.
 30. Thesupport surface attachment device according to claim 1, furthercomprising a conduit mounting member configured to mount electricalconduit of a photovoltaic system to an upstanding base member of saidbase assembly, said conduit mounting member including a securementportion comprising one or more mounting apertures for attaching saidconduit mounting member to said upstanding base member, said conduitmounting member further comprising a conduit mounting portion connectedto said securement portion, said conduit mounting portion comprising oneor more securement apertures for attaching said electrical conduit tosaid conduit mounting member.
 31. A coupling device configured to attachone or more photovoltaic modules to one or more other photovoltaicmodules, said coupling device comprising: a lower coupling memberincluding at least one ledge extending outwardly from a side surface ofsaid lower coupling member, said lower coupling member further includingone or more first teeth disposed thereon; and an upper coupling memberincluding at least one flange portion extending outwardly from saidupper coupling member, said upper coupling member further including oneor more second teeth disposed thereon, said upper coupling member beingadjustably connected to said lower coupling member by at least onefastening device, said one or more first teeth on said lower couplingmember configured to engage said one or more second teeth on said lowercoupling member when said at least one fastening device is beingtightened so as to maintain a minimum gap between said upper couplingmember and said lower coupling member for receiving one or morephotovoltaic module frames of said one or more photovoltaic modules whensaid one or more photovoltaic modules are pivotably installed into afirst side of said clamp assembly; and wherein said one or more otherphotovoltaic modules are configured to be clamped between said at leastone ledge of said lower coupling member and said at least one flangeportion of said upper coupling member.
 32. The coupling device accordingto claim 31, wherein said at least one flange portion of said uppercoupling member comprises a plurality of spaced-apart apertures disposedthererough, and wherein said at least one fastening device comprises afirst and second fastening device, a first one of said plurality ofspaced-apart apertures comprising a fastener hole for receiving saidfirst fastening device, and said second one of said plurality ofspaced-apart apertures comprising a fastener slot for receiving saidsecond fastening device, said fastener slot providing clearance so as toallow said tightening of one of said first and second fastening devicesprior to the tightening of the other of said first and second fasteningdevices.
 33. The coupling device according to claim 32, wherein said atleast one flange portion of said upper coupling member comprises acentral slot disposed between said first one of said plurality ofspaced-apart apertures and said second one of said plurality ofspaced-apart apertures, said central slot configured to receive afastener member for connecting said coupling device to a glider memberof a support surface attachment device so that said coupling device iscapable of being used with a base assembly of said support surfaceattachment device for attaching said one or more photovoltaic modules toa support surface.
 34. The coupling device according to claim 31,wherein a top surface of said at least one flange portion of said uppercoupling member comprises one or more visual installation guide marks toindicate locational limits of mounting said one or more photovoltaicmodules within said coupling device.
 35. The coupling device accordingto claim 31, wherein said lower coupling member comprises one or moremating grooves and one or more mating protrusions for engaging with oneor more mating protrusions and one or more mating grooves of a skirtmember.
 36. The coupling device according to claim 35, wherein said oneor more mating protrusions of said lower coupling member comprise aplurality of mating protrusions disposed in alternating upward anddownward orientations so that said coupling device is capable ofremaining in engagement with said skirt member prior to said at leastone fastening device being tightened by an installer.
 37. The couplingdevice according to claim 31, wherein said lower coupling membercomprises one or more water drainage troughs formed therein for drainingwater from said one or more photovoltaic modules.
 38. A bonding clipconfigured to ground one or more photovoltaic modules, said bonding clipcomprising: a clip body portion having a first surface and a secondsurface disposed opposite to said first surface, said clip body portionfurther including a plurality of protruding members, at least one ofsaid plurality of protruding members projecting outwardly from saidfirst surface in a first direction, and at least another of saidplurality of protruding members projecting outwardly from said secondsurface in a second direction, said first direction being generallyopposite to said second direction; and one or more clip attachmentportions connected to said clip body portion, said one or more clipattachment portions configured to attach said bonding clip to an objecton which said bonding clip is mounted.
 39. The bonding clip according toclaim 38, wherein said plurality of protruding members are arranged in agenerally staggered pattern along a length of said clip body portion.40. The bonding clip according to claim 38, wherein said clip bodyportion is in the form of a flat plate that does not comprise any foldsformed therein.
 41. The bonding clip according to claim 38, wherein saidone or more clip attachment portions comprise a plurality of bent tabmembers, said plurality of bent tab members configured to engage with agroove in said object.
 42. The bonding clip according to claim 38,wherein said one or more clip attachment portions comprise a pair offlange members, each of said pair of flange members being disposed at anopposite end of said clip body portion; and wherein, when said bondingclip is installed on said object, a top portion of each of said pair offlange members remains visible to an installer so that an installedcondition of said bonding clip is capable of being verified by saidinstaller.
 43. A power accessory bracket configured to attach one ormore power accessories of a photovoltaic system to one or more frames ofone or more photovoltaic modules, said power accessory bracketcomprising: a bracket body portion having a first side and a second sidedisposed opposite to said first surface; a first plurality of teethdisposed on said first side of said bracket body portion, said firstplurality of teeth configured to engage said one or more frames of saidone or more photovoltaic modules; and a second plurality of teethdisposed on said second side of said bracket body portion, said secondplurality of teeth configured to engage one or more mounting members ofsaid one or more power accessories; wherein said power accessory bracketis configured to provide electrical bonding of said one or morephotovoltaic modules to said one or more power accessories.
 44. Thepower accessory bracket according to claim 43, wherein at least one ofsaid first and second pluralities of teeth extend below a bottom surfaceof said bracket body portion so as to provide said electrical bondingand to accommodate a plurality of different photovoltaic module flangedimensions.
 45. The power accessory bracket according to claim 43,wherein said bracket body portion comprises at least one mountingaperture disposed therethrough, said at least one mounting aperturebeing offset from a center position of said bracket body portion in awidthwise direction of said bracket body portion so as to accommodate aplurality of different photovoltaic module flange dimensions by allowingsaid power accessory bracket to positioned in two differentorientations.
 46. The power accessory bracket according to claim 45,wherein said bracket body portion comprises at least one additionalaperture formed therein for accommodating one or more components of oneor more power accessories.